Liquid cooling heat exchange device

Abstract

The utility model discloses a liquid cooling heat exchange device is arranged in the server rack, including box, primary side flow path, secondary side flow path and heat exchanger. Among them, the box has the containing area, the containing area includes the first direction and the second direction of each other, primary side flow path, secondary side flow path and heat exchanger are placed in the containing area, secondary side flow path includes two water pumps, two water pumps are located in the first direction on the side of heat exchanger, and the outlet pipeline of two water pumps spans the top of heat exchanger and extends to the secondary side outlet of box in the first direction, primary side flow path is located in the first direction on the other side of heat exchanger. The CDU structure of the utility model is compact, and higher power density can be realized.

Description

Technical Field

[0001] This utility model relates to the field of heat dissipation devices, specifically to a liquid-cooled heat exchange device. Background Technology

[0002] Cooling distribution units (CDUs), as core components of cold plate liquid cooling systems, play a crucial role in high-density computing scenarios such as data centers and intelligent computing centers. With the rapid development of technologies such as AI and high-performance computing (HPC), the CDU market is experiencing a period of rapid growth. Utility Model Content

[0003] The purpose of this invention is to provide a liquid-cooled heat exchange device.

[0004] According to one aspect of the present invention, a liquid-cooled heat exchange device is provided, which is arranged in a server rack and includes a housing, a primary flow path, a secondary flow path and a heat exchanger.

[0005] in,

[0006] The housing has a receiving area, which includes a first direction and a second direction that intersect each other, and the receiving area is longer in the first direction than in the second direction;

[0007] The primary side flow path, the secondary side flow path, and the heat exchanger are placed in the receiving area, and the heat exchanger is connected to the primary side flow path and the secondary side flow path;

[0008] The heat exchanger is arranged in full width in the receiving area in the second direction, and the heat exchanger is longer in the second direction than in the first direction;

[0009] The secondary side flow path includes two water pumps, which are located on one side of the heat exchanger in the first direction, and the outlet pipes of the two water pumps cross the top of the heat exchanger and extend to the secondary side outlet of the housing in the first direction;

[0010] The primary flow path is located on the other side of the heat exchanger in the first direction.

[0011] According to some embodiments, the primary side inlet and primary side outlet of the heat exchanger are arranged on a first flow path connection surface in the second direction and are arranged opposite to each other in the second direction; the secondary side inlet of the heat exchanger is arranged on the first flow path connection surface, and the secondary side outlet of the heat exchanger is arranged on a second flow path connection surface in the second direction, with the secondary side inlet and secondary side outlet of the heat exchanger arranged diagonally.

[0012] According to one example, the secondary inlet of the heat exchanger is located above the primary outlet of the heat exchanger.

[0013] The primary inlet and primary outlet of the housing are located on the same side as the primary outlet of the heat exchanger in the second direction; the secondary inlet of the housing is located on the other side in the second direction, and the secondary outlet of the housing is located between the secondary inlet and the primary inlet of the housing.

[0014] According to some embodiments, the two water pumps are arranged in the first direction.

[0015] According to some embodiments, the outlet pipes of the two water pumps are straight pipes.

[0016] According to some embodiments, the secondary side flow path includes a water tank, which is connected to the secondary side outlet of the heat exchanger in the first direction and to the inlet pipes of the two water pumps in the second direction.

[0017] According to some embodiments, the secondary side flow path includes a check valve, which is arranged between the outlet pipes of the two water pumps and the secondary side outlet of the tank.

[0018] According to one example, the check valve is an integrated check valve with two inlets and one outlet. The two inlets of the check valve are respectively connected to the outlet pipelines of the two water pumps, and the single outlet of the check valve is connected to the secondary outlet of the housing.

[0019] According to some embodiments, a control unit is also included, which is placed in the receiving area and is located on the side of the two water pumps away from the heat exchanger in the first direction.

[0020] According to one example, the control unit is arranged with an interactive device in the second direction.

[0021] According to some embodiments, a power module is also included, which is placed in the receiving area and is located on the side of the two water pumps away from the heat exchanger in the first direction.

[0022] According to some embodiments, the coolant flowing in through the primary side flow path has a higher temperature than the coolant flowing in through the secondary side flow path, and the two exchange heat within the heat exchanger.

[0023] According to some embodiments, the liquid-cooled heat exchanger is a CDU.

[0024] According to one example, the liquid-cooled heat exchanger is a 4U rack-mounted CDU.

[0025] The volume of a single water pump is no greater than 1L.

[0026] Compared with existing technologies, the liquid-cooled heat exchanger of this invention adopts an innovative layout design, with clear and concise wiring between components. Multiple flexible hoses and stainless steel elbows are used in the piping to improve the compactness of the component layout and further reduce the length dimension of the housing (i.e., the depth dimension in the X direction). Through a rational layout, the heat exchanger is placed in the central area of ​​the CDU, allowing the selection of plate heat exchangers with large heat exchange areas and low flow resistance, resulting in higher energy density (heat exchange / heat exchanger volume). Furthermore, the high proportion of quick-installation clamps used in the pipe connections greatly improves the convenience of installation and maintenance.

[0027] 4U rack-mount CDUs have become the mainstream solution for data centers and manufacturers due to their compact size (occupying only 4U of space), direct insertion into 19-inch standard racks, and flexible deployment. Within the limited CDU size, typically a 4U rack-mount CDU, this invention achieves a significant power density increase within a 4U space by reducing pump volume through a reasonable and compact layout, while simultaneously improving the pump's power-to-weight ratio. Furthermore, by selecting plate heat exchangers with large heat exchange areas and low flow resistance, it optimizes flow resistance, allowing the pump to drive a flow rate exceeding 160 kW with less than 1 kW of power consumption. Under the same operating conditions, a single heat exchanger can stably output more than 160 kW of heat exchange, resulting in a COP (heat exchange / pump power consumption) of over 160 for the entire system.

[0028] The CDU of this utility model also includes a water pump with a high power-to-weight ratio, which has the following characteristics: ① the pump volume is no more than 1L; ② the maximum flow rate can reach 200L / min when the rated power is 900W, and the pressure head is as high as 230kPa; ③ the power density is as high as 900W / dm3; ④ the coreless motor is made of rare earth and nanocomposite materials.

[0029] By arranging the heat exchanger as a whole in the middle area of ​​the CDU, the primary flow path as a whole on one side of the heat exchanger, and the water pump of the secondary flow path on the other side of the heat exchanger, the CDU of this invention has high uniformity of overall weight distribution, and the weight distribution ratio in the depth (X direction) and width (Y direction) directions is close to 50:50. Attached Figure Description

[0030] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the following description of the embodiments will be briefly introduced. The drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this utility model. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.

[0032] Figure 1 This is a schematic diagram of a data center liquid cooling system according to an embodiment of the present invention;

[0033] Figure 2 This is a three-dimensional structural schematic diagram of a liquid-cooled heat exchange device according to an embodiment of the present invention;

[0034] Figure 3 This is a three-dimensional structural schematic diagram of a liquid-cooled heat exchange device according to an embodiment of the present invention;

[0035] Figure 4 This is a schematic diagram of the primary side flow path in a liquid-cooled heat exchanger according to an embodiment of the present invention;

[0036] Figure 5 This is a schematic diagram of the secondary flow path in a liquid-cooled heat exchanger according to an embodiment of the present invention. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the described embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model. It is understood that, without conflict, some technical means of the various embodiments described herein can be substituted for or combined with each other.

[0038] In the description of this utility model specification and claims, the terms "first," "second," etc., are used only to distinguish the described objects and do not have any sequential or technical meaning. Therefore, objects specified with "first," "second," etc., may explicitly or implicitly include one or more of those objects. Furthermore, the words "a" or "one," etc., do not indicate a quantity limitation, but rather indicate the presence of at least one, while "multiple" indicates at least two.

[0039] In the description of this utility model and its claims, terms such as "connect," "install," "fix," and "retain" should be interpreted broadly unless otherwise specified. For example, "connect" can mean a separate connection or an integral connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean a non-detachable connection or a detachable connection. As another example, "retain" does not necessarily mean complete containment; this concept also includes the containment of parts that protrude externally. Those skilled in the art can understand the specific meaning of the aforementioned terms in this utility model according to the specific circumstances.

[0040] In the description of this utility model and the claims, the term "intersection" should be interpreted broadly unless otherwise specified. For example, "intersection" can include situations where lines intersect each other, surfaces intersect each other, or lines and surfaces intersect each other at right angles. Furthermore, the term "intersection" can also include situations where lines intersect each other, surfaces intersect each other, or lines and surfaces intersect each other non-right angles within a small tolerance range. Small tolerances include both tolerances and errors.

[0041] In the description of this utility model and its claims, the terms "upper," "lower," "horizontal," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the drawings, are only for the purpose of clearly and simply describing this utility model, and do not indicate or imply that the elements referred to must have a specific orientation or be constructed and operated in a specific orientation. These directional terms are relative concepts used for relative description and clarification, and can change accordingly depending on the orientation of the components in the drawings. For example, if the device in the drawings is flipped, an element described as "below" other elements will be positioned "above" other elements.

[0042] In the description of this utility model specification and claims, the term "if" is generally interchangeable with "when," "at," "in response to determination," or "in response to detection," depending on the context.

[0043] In the description of this utility model specification and claims, if there is a "direction" in relation to connection and / or movement, including connection and / or movement with directional components, the term "in direction" is not necessarily understood to mean connection and / or movement only in that one direction. Those skilled in the art can understand the specific meaning of the aforementioned terms in this utility model according to the specific circumstances.

[0044] The following will refer to the appendix Figure 1-5 The following describes and illustrates various exemplary embodiments of the present invention.

[0045] See Figure 1A typical data center liquid cooling system includes a primary side, a secondary side, and a liquid cooling heat exchanger 30. The liquid cooling heat exchanger 30 is typically a CDU (Cooling Distribution Unit). As the core component of the liquid-liquid heat exchange loop between the primary and secondary sides of the data center, the CDU 30 is the pivotal component for heat exchange throughout the entire data center.

[0046] The low-temperature coolant on the primary side originates from outdoor heat dissipation facilities, such as cooling towers and chillers. These facilities have cooled the coolant to a specific temperature, such as 25°C-32°C (depending on the environment). The coolant can be various water-based coolants, such as water or ethylene glycol aqueous solutions. The low-temperature coolant flowing from the heat dissipation facilities enters CDU 30 through the primary side inlet and then into the primary side flow channel of the plate heat exchanger. Inside the plate heat exchanger, the low-temperature coolant on the primary side and the high-temperature coolant on the secondary side undergo efficient heat exchange. The low-temperature chilled water on the primary side absorbs heat from the high-temperature coolant on the secondary side, increasing its own temperature (e.g., from 28°C to 33°C). The heated hot water flows out of the heat exchanger and exits through the primary side outlet of CDU 30. This hot water, carrying heat from the secondary side of the data center, returns to outdoor cooling towers and other facilities through primary side pipes, dissipating the heat into the atmosphere, being cooled again, and starting the next cycle.

[0047] On the secondary side, the coolant flows through the liquid-cooled server cold plates in each rack of the data center, absorbing the heat generated by chips such as CPUs and GPUs, causing its temperature to rise significantly (e.g., from 40°C to 50°C). The high-temperature coolant flowing out of the server cold plates enters the secondary side flow channel of the plate heat exchanger through the secondary side inlet of the CDU 30. Inside the plate heat exchanger, the hot coolant on the secondary side transfers heat to the cooler primary side coolant on the other side of the plate, reducing its own temperature (e.g., from 50°C to 40°C). The cooled secondary side coolant flows out from the secondary side outlet of the CDU 30 and is redistributed to the liquid-cooled servers in each rack, beginning the next cooling cycle.

[0048] Here, the primary-side coolant and secondary-side coolant can be the same or different. For example, antifreeze and pure water can be used as both primary and secondary-side coolants. Specifically, antifreeze that can be used as a coolant includes aqueous solutions of ethylene glycol and propylene glycol. Through the heat exchange process between the primary and secondary sides, the CDU 30 achieves efficient heat transfer from the server to the external environment, ensuring isolation between the internal coolant (secondary side) and the external circulating coolant (primary side) of the data center, thus ensuring the safety and reliability of the data center.

[0049] In some embodiments, the CDU 30 is a rack-mounted CDU, directly installed / integrated within a single rack to achieve efficient heat dissipation within the server rack. As an example, the CDU 30 is 4U in size, where U is the height of a rack unit (1U = 1.75 inches ≈ 44.45 mm). The standard rack width is fixed at 19 inches (approximately 482.6 mm), and common depths range from 24 to 36 inches (approximately 610 to 914 mm), with different depths corresponding to different types of equipment (such as network switches, servers, GPU clusters, etc.).

[0050] See Figure 2-5 The CDU 30 includes a housing 1, a primary side flow path 10, a secondary side flow path 20, and a heat exchanger 3. The housing 1 has a receiving area 100, which includes a first direction and a second direction that intersect each other, and the receiving area 100 is longer in the first direction than in the second direction.

[0051] In this specification, for ease of understanding and explanation, the structure and configuration of the components in the CDU 30 are described using an XYZ coordinate system. In the following description, the direction along the X-axis is referred to as the X-direction, the direction along the Y-axis as the Y-direction, and the direction along the Z-axis as the Z-direction. In some embodiments, the X-direction can be referred to as the "first direction," the Y-direction as the "second direction," and the Z-direction as the "third direction." Therefore, the receiving area 100 is longer in the X-direction than in the Y-direction; that is, the receiving area 100 is approximately rectangular with the X-direction as its longer side (depth) and the Y-direction as its shorter side (width). Furthermore, the receiving area 100 has its height along the Z-direction.

[0052] The enclosure 1 has multiple panels to surround and form a receiving area 100. The front panel 31 and rear panel 32 are configured opposite each other in the X direction, with the distance between them not exceeding the depth of the rack to allow for piping installation between the primary and secondary sides. The front panel 31 provides components for user interaction, such as a large control panel and pull-out handles, while the rear panel 32 provides piping inlets and outlets. The two side panels 33 and 34 are configured opposite each other in the Y direction, with the distance between them typically consistent with a standard rack width of 19 inches. The top and bottom panels (not shown) are configured opposite each other in the Z direction, with the distance between them typically, for example, 4U. For ease of description and illustration of the components in the CDU 30, the top panel has been removed in all figures, and the bottom panel is not shown.

[0053] The primary side flow path 10, the secondary side flow path 20, and the heat exchanger 3 are placed in the housing area 100 of the casing 1.

[0054] The primary side flow path 10 is the flow path for the primary side coolant, and the secondary side flow path 20 is the flow path for the secondary side coolant. The heat exchanger 3 is connected to both the primary side flow path 10 and the secondary side flow path 20. Heat exchange occurs between the primary and secondary side coolants within the heat exchanger 3.

[0055] The heat exchanger 3 is typically a plate heat exchanger. For example, the heat exchanger 3 has multiple heat transfer plates (not shown) stacked in the Y direction. Each heat transfer plate has its thickness along the Y direction. Each heat transfer plate is approximately rectangular in shape with the X direction as its long side and the Z direction as its short side. Inside the heat exchanger 3, the surface of each heat transfer plate forms a flow path for the coolant. Heat transfer plates for primary-side coolant flow and heat transfer plates for secondary-side coolant flow are stacked alternately. Thus, heat from the high-temperature coolant on the secondary side is transferred to the heat transfer plates, and this heat moves to the low-temperature coolant on the primary side.

[0056] Heat exchanger 3 allows for efficient heat exchange between the low-temperature coolant on the primary side and the high-temperature coolant on the secondary side while maintaining physical isolation. The primary side's cold source removes heat from the server on the secondary side. By separating the external large-scale cooling system from the internal cooling cycle of the IT equipment, the purity of the secondary side coolant is ensured.

[0057] The primary side inlet, primary side outlet, secondary side inlet, and secondary side outlet of housing 1 are all located on the rear panel 32. For example, the rear panel 32 has four openings extending through the X direction, which do not overlap in the Z direction. The primary side inlet and primary side outlet of housing 1 are arranged on one side in the Y direction for mounting the primary side inlet connector 11 and primary side outlet connector 12 of the primary side flow path 10. The primary side outlet (and primary side outlet connector 12) are closer to the side plate 34 in the X direction than the primary side inlet (and primary side inlet connector 11). The secondary side inlet of housing 1 is arranged on the other side in the Y direction for mounting the secondary side inlet connector 21 of the secondary side flow path 20. The secondary side outlet of housing 1 is arranged between the secondary side inlet and the primary side outlet for mounting the secondary side outlet connector 22 of the secondary side flow path 20.

[0058] The primary side inlet of housing 1 is connected to the primary side flow path 10 via primary side inlet connector 11, and is the inlet for primary side coolant to flow into the CDU 30. The primary side outlet of housing 1 is connected to the primary side flow path 10 via primary side outlet connector 12, and is the outlet for primary side coolant to flow out of the CDU 30.

[0059] The low-temperature coolant on the primary side flows into the primary side flow path 10 inside the CDU 30 from the external heat dissipation facility through the primary side inlet connector 11. After heat exchange with the secondary side, the high-temperature coolant returns to the heat dissipation facility from the primary side flow path 10 inside the CDU 30 through the primary side outlet connector 12 for recooling.

[0060] The secondary side inlet of housing 1 is connected to the secondary side flow path 20 via secondary side inlet connector 21, and is the inlet for secondary side coolant to flow into the CDU 30. The secondary side outlet of housing 1 is connected to the secondary side flow path 20 via secondary side outlet connector 22, and is the outlet for secondary side coolant to flow out of the CDU 30.

[0061] The high-temperature coolant, after absorbing heat from the server / chip on the secondary side, flows from the server cold plate into the secondary flow path 20 inside the CDU 30 through the secondary side inlet connector 21. After being cooled by heat exchange with the primary side, the low-temperature coolant returns to the server cold plate from the secondary side flow path 20 inside the CDU 30 through the secondary side outlet connector 22, so as to reabsorb heat from the server / chip.

[0062] The containment area 100 is divided into three sub-areas in the X direction by the water tank 24 of the secondary side flow path 20, the heat exchanger 3, and the primary side flow path 10, namely sub-areas A, B, and C.

[0063] Heat exchanger 3 is located in the middle of the three sub-regions, namely sub-region B. It should be noted that sub-region B does not necessarily have to be centered in the X-direction; it simply needs to be located between the other two sub-regions. Here, a plate heat exchanger with a large heat exchange area and low flow resistance can be selected, resulting in a higher energy density (heat exchanged / heat exchanger volume).

[0064] The primary side flow path 10 is located on the side of the heat exchanger 3 closest to the rear panel 32, i.e., sub-region C. The water pump 23 and water tank of the secondary side flow path 20 are located on the side of the heat exchanger 3 closest to the front panel 31, i.e., sub-region A.

[0065] Aside from necessary assembly gaps, the heat exchanger 3 essentially occupies the entire sub-region B, meaning it is fully positioned within the housing area 100 in the Y direction. In other words, the size of the heat exchanger 3 in the Y direction is comparable to that of the housing area 100 in the Y direction, and the two side walls of the heat exchanger 3 are flush with the X direction of the housing area 100. For example, if the heat exchanger 3 is rectangular with the Y direction as its long side and the X direction as its short side, then the long side of the heat exchanger 3 is approximately 19 inches, and the two short sides are essentially flush with the side plates 33 and 34 of the housing 1, leaving only a small assembly allowance for a micro-gap installation. The fact that the heat exchanger 3 occupies the entire housing area 100 in the Y direction allows for the use of more heat transfer plates. As the size of the heat exchanger 3 increases in the X direction, the surface area of ​​each heat transfer plate also increases, further increasing the heat exchange capacity of the heat exchanger 3 and thus improving the cooling performance of the CDU 30.

[0066] The flow path connection surfaces of heat exchanger 3 are on the two long sides in the Y direction. The primary side inlet and outlet of heat exchanger 3 are both located on the long side facing the primary flow path 10, i.e., the first flow path connection surface, and are arranged opposite each other in the Y direction, meaning the primary side inlet and outlet are located on opposite sides of heat exchanger 3 in the Y direction. The secondary side inlet and outlet of heat exchanger 3 are respectively arranged on the diagonals of the two long sides, i.e., the secondary side inlet of heat exchanger 3 is located on the first flow path connection surface, and the secondary side outlet of heat exchanger 3 is located on the second flow path connection surface, and are arranged diagonally. The secondary side inlet and primary side outlet of heat exchanger 3 overlap in the Z direction, and the secondary side inlet is located above the primary side outlet.

[0067] The primary side flow path 10 includes a primary side inlet connector 11, a primary side inlet pipe, a primary side outlet pipe, and a primary side outlet connector 12. The primary side coolant enters the primary side inlet of the heat exchanger 3 through the primary side inlet connector 11 and the primary side inlet pipe. After heat exchange with the secondary side coolant within the heat exchanger 3, it flows out from the primary side outlet of the heat exchanger 3 to the primary side outlet pipe, and then returns to the primary side outdoor heat dissipation facility, such as a cooling tower, via the primary side outlet connector 12. The primary side flow path 10 is entirely located within sub-region A, which simplifies the piping of the primary side flow path 10 and makes its structure more compact.

[0068] The primary side inlet pipe includes a straight section and a bend section. The bend section allows the primary side cryogenic coolant to flow from the primary side inlet joint 11 located on one side in the Y direction to the primary side inlet of the heat exchanger 3 located on the other side in the Y direction.

[0069] An electric regulating valve 13 is also installed on the primary side inlet pipe. It automatically adjusts the valve opening by receiving a signal (4-20mA) from the control unit 4, thereby precisely controlling the flow rate of the primary side coolant in the pipe. The electric regulating valve 13 controls the cooling intensity on the secondary side by adjusting the flow rate of the external cold source (such as cold water), thereby precisely controlling the outlet water temperature of the secondary side.

[0070] The primary side outlet pipe is a straight pipe, so that the primary side coolant after heat absorption flows from the primary side outlet of heat exchanger 3 to the primary side outlet connector 12 which is in a straight line with the primary side outlet in the X direction.

[0071] A flow meter 14 is also installed on the primary side outlet pipe, which measures and displays the flow rate of the primary side coolant in the pipe in real time. If the flow rate is abnormally reduced, it may indicate a clogged filter, a bent pipe, a faulty water pump, or air in the system.

[0072] The secondary side flow path 20 includes a secondary side inlet connector 21, a secondary side inlet pipe, a water tank 24 (including inlet and outlet pipes), a water pump 23, a secondary side outlet pipe, and a secondary side outlet connector 22. The secondary side coolant enters the secondary side inlet of the heat exchanger 3 through the secondary side inlet connector 21 and the secondary side inlet pipe. After transferring heat to the low-temperature coolant on the primary side in the heat exchanger 3, it flows out from the secondary side outlet of the heat exchanger 3 through the water tank 24 to the water pump 23. The water pump 23 then returns the cooled secondary side coolant to the server cold plate on the secondary side through the secondary side inlet pipe and the secondary side outlet connector 22.

[0073] The secondary side inlet pipe includes a straight pipe section and a bend section. The bend section allows the high-temperature coolant on the secondary side to flow from the secondary side inlet joint 21 located on one side of the Y direction to the secondary side inlet of the heat exchanger 3 located on the other side of the Y direction.

[0074] A leak detection line 29 and a flow meter 26 are also installed on the secondary side inlet pipe. The leak detection line 29 is a sensing cable located at the pipe interface. When coolant leaks and comes into contact with this cable, it changes its electrical characteristics (such as resistance), thus triggering an alarm. Leak detection lines can be installed at other pipe interfaces within the CDU 30, but are not shown here. The flow meter 26 measures and displays the flow rate of the secondary side coolant in the pipe in real time. If this flow rate decreases abnormally, it may indicate a clogged filter, a bent pipe, a faulty water pump, or air in the system.

[0075] The inlet pipe of water tank 24 is connected to the secondary side outlet of heat exchanger 3 along the X direction, and the outlet pipe of water tank 24 is connected to the inlet of two water pumps 23 along the Y direction.

[0076] The water tank 24 is used to compensate for the thermal expansion and contraction of the secondary side coolant. Changes in liquid temperature will cause changes in volume. The water tank provides a buffer space to maintain stable system pressure. Maintaining stable system pressure ensures that the suction end of the water pump 23 has sufficient pressure head and prevents cavitation.

[0077] The water tank 24 is also equipped with a level sensor 241 to monitor the liquid level in the tank in real time, ensuring stable system operation. The level sensor 241 continuously provides feedback on the remaining liquid level in the tank and triggers an alarm or activates a drainage device when the level is too high to prevent liquid overflow and damage to the equipment. It also provides timely warnings when the level is too low to avoid pump burnout or system shutdown due to liquid interruption. The level sensor 241 also provides data support for system flow regulation and troubleshooting (e.g., an abnormal drop in liquid level may indicate a pipeline leak).

[0078] The water tank 24 is also equipped with a pressure relief valve 271 and an exhaust port 281, which are connected to the pressure relief port 272 and the exhaust port 282 on the rear panel via pipes that cross over other components. When the system pressure rises abnormally and exceeds the set value due to some fault (such as excessive temperature rise, water pump overload, valve misoperation), the pressure relief valve 271 will automatically open and release pressure through the pressure relief port 272. The exhaust port 281 and the exhaust port 282 will also open at the same time to release air, thereby protecting the pressure-bearing components such as pipes, pipe interfaces, and heat exchanger 3 from damage.

[0079] The two water pumps 23 are redundant (1+1). The inlet pipes of the two water pumps 23 are also the outlet pipes of the water tank 24, and the outlet pipes are also the secondary side outlet pipes. The two outlet pipes of the two water pumps 23 cross the top of the heat exchanger 3 and extend in the X direction to the secondary side outlet of the tank 1. The two outlet pipes can be straight pipes, crossing the top of the heat exchanger 3 in the X direction and running straight to the secondary side outlet connector 22. This not only reduces the complexity of the piping of the secondary side flow path 20, but also effectively reduces the volume occupied by the secondary side flow path 20.

[0080] When the volume of the water pump is also reduced, the advantages of this CDU will become more apparent. In conjunction with the foregoing, the primary flow path 10 is located on one side of the heat exchanger 3, and the water pump of the secondary flow path 20 is located on the other side of the heat exchanger 3. When the occupancy of the primary flow path 10 and the secondary flow path 20 within the accommodating area 100 is effectively controlled, the size of the heat exchanger 3 between them will be larger, thereby improving the heat exchange capacity of the CDU 30.

[0081] In this invention, while the volume of the water pump 23 is reduced, its power-to-weight ratio is significantly improved. The water pump 23, for example, is a DC brushless centrifugal pump that provides power to continuously circulate the secondary-side coolant in a closed loop, flowing into the heat exchanger 3 within the CDU 30 and returning to the cold plate of the server rack to remove heat. According to one example, the water pump 23 can be a high power-to-weight ratio pump using a coreless motor made of rare-earth and nanocomposite materials, achieving a maximum flow rate of 200 L / min at a rated power of 900 W, a head of up to 230 kPa, a power density of up to 900 W / dm³, and a pump volume of no more than 1 L.

[0082] A check valve 25 can also be installed between the two outlet pipes of the water pump 23 and the secondary outlet of the housing 1. Therefore, the check valve 25 is an integrated check valve with two inlets and one outlet, with a U-shaped cavity structure, small size, and low flow resistance. The two U-shaped openings serve as inlets connected to the two outlet pipes of the two water pumps 23 respectively, and an outlet is arranged at the bottom of the U-shape to connect to the secondary outlet of the housing 1.

[0083] As described above, the two water pumps 23 are redundant (1+1), with only one pump operating at a time and the other as a standby. The check valve 25 prevents backflow of liquid when the pumps stop, avoiding water hammer or reverse rotation of the pump 23. The two water pumps 23 are arranged in the X direction.

[0084] Flexible hoses and stainless steel elbows can be used in the piping of the primary side flow path 10 and the secondary side flow path 20 to improve the compactness of the CDU 30 layout, thereby further reducing the size of the housing 1 in the X direction (depth). Quick-connect chucks can be used for the pipe connections, and the high usage rate of quick-connect chucks can greatly improve the convenience of installation and maintenance.

[0085] Those skilled in the art will know that filters, temperature sensors, and pressure sensors may also be provided in the primary side flow path 10 and the secondary side flow path 20.

[0086] The primary function of the filter on the primary side is to protect the CDU 30 itself and the external refrigeration system (heat dissipation facilities). The coolant circulating on the primary side comes from the external environment (such as a cooling tower) or exchanges heat with a large chiller unit. Such a loop is prone to introducing various impurities. By installing a filter in the primary side flow path 10, the heat exchanger 3 can be prevented from being blocked. At the same time, most solid particles can be removed, reducing the accumulation of dirt in the entire primary side piping system (pipes, valves, water pumps, etc.) from the source, reducing the intensity of daily maintenance and the risk of long-term operation.

[0087] The primary function of the secondary-side filter is to protect the IT equipment (server) and the secondary-side water pump 23. The secondary-side loop is an internally closed clean circulation system that directly dissipates heat from the server chips. The flow channels inside the server's cold plate are extremely precise and narrow, thus requiring a filter to prevent clogging. Furthermore, although the secondary-side water pump 23 is a DC brushless centrifugal pump designed for high-purity coolant, microparticles can still cause long-term wear; therefore, the filter also prevents pump wear.

[0088] The temperature sensor can be a PT100 platinum resistance thermometer to monitor the temperature of the primary and secondary coolants at different key points in real time. The control unit 4 adjusts the speed of the water pump 23 and instructs the electric regulating valve 13 to adjust the valve opening based on the temperature difference. Specific functions and layout include:

[0089] ① Primary side inlet: Monitor the temperature of the coolant at the primary side inlet of CDU 30;

[0090] ② Primary outlet of heat exchanger 3: Monitor the temperature of the coolant at the primary outlet of CDU 30;

[0091] ③ Secondary side inlet: Monitor the temperature of the coolant from the server cold plate to the secondary side inlet of CDU 30;

[0092] ④ Secondary outlet: Monitor the temperature of the coolant supplied to the server cold plate after heat exchange by heat exchanger 3.

[0093] Pressure sensors monitor the pressure at key points in the circulation loop, ensuring the CDU 30 operates within a safe pressure range. This is a crucial indicator of system health (e.g., blockage, leakage). Specific functions and layout include:

[0094] ① Primary side inlet: Monitor the pressure at the primary side inlet of CDU 30;

[0095] ② Primary side outlet: Monitor the pressure at the primary side outlet of CDU 30;

[0096] ③ Secondary side inlet: Monitor the pressure at the secondary side inlet of CDU30;

[0097] ④ Secondary side outlet: Monitor the pressure at the secondary side outlet of CDU 30.

[0098] Sub-area A also houses the control unit 4 and the power module 5. In the Y direction, adjacent to the front panel, the water tank 24, control unit 4, and power module 5 are arranged sequentially. In the X direction, both the control unit 4 and the power module 5 are located on the side of the two water pumps 23 furthest from the heat exchanger 3.

[0099] The front panel 31 of the housing 1 has an opening that extends through the X direction to accommodate and expose the interactive device of the control unit 4, typically a large-size LCD screen, such as a 7-inch screen, which increases the amount of information displayed on a single screen and expands the human-computer interaction field of view compared to the current mainstream 4-inch screen.

[0100] The control unit, as the electrical control component of the CDU 30, uses a PLC for control. Information such as temperature, pressure, flow rate, liquid level, and humidity are all collected by the PLC. The collected information is then used by the PLC's PID calculations to control the water pump flow and valve opening. The PLC also needs to upload various operating information from the CDU 30 to the touchscreen on the CDU's front panel for real-time display. Furthermore, to support remote functionality, the PLC integrates remote control capabilities, enabling remote control and monitoring.

[0101] This utility model's CDU adopts an innovative layout design, with clear and concise wiring between components. Multiple flexible hoses and stainless steel elbows are used in the piping to improve the compactness of the component layout and further reduce the length dimension of the housing (i.e., the depth dimension in the X direction). Through a rational layout, the heat exchanger is placed in the central area of ​​the CDU, allowing the selection of plate heat exchangers with large heat exchange areas and low flow resistance, resulting in higher energy density (heat exchange / heat exchanger volume). Furthermore, a high proportion of quick-connect clamps are used for pipe connections, greatly improving the convenience of installation and maintenance.

[0102] Within a limited CDU size, the CDU of this invention can achieve higher power density. The heat exchange of a 4U size CDU can reach over 160kW, and the cooling efficiency COP (CDU rated cooling capacity / CDU power consumption) can reach over 160.

[0103] The CDU of this utility model also includes a water pump with a high power-to-weight ratio, featuring: ① a coreless motor made of rare earth and nanocomposite materials; ② a maximum flow rate of 200L / min and a head of up to 230kPa when the rated power is 900W; ③ a power density of up to 900W / dm3; and ④ a pump volume of no more than 1L.

[0104] By arranging the heat exchanger as a whole in the middle area of ​​the CDU, the primary flow path as a whole on one side of the heat exchanger, and the water pump of the secondary flow path on the other side of the heat exchanger, the CDU of this invention has high uniformity of overall weight distribution, and the weight distribution ratio in the depth (X direction) and width (Y direction) directions is close to 50:50.

[0105] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0106] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A liquid-cooled heat exchange device, arranged in a server rack, comprising a housing, a primary flow path, a secondary flow path, and a heat exchanger; in, The housing has a receiving area, which includes a first direction and a second direction that intersect each other, and the receiving area is longer in the first direction than in the second direction; The primary side flow path, the secondary side flow path, and the heat exchanger are placed in the receiving area, and the heat exchanger is connected to the primary side flow path and the secondary side flow path; The heat exchanger is arranged in full width in the receiving area in the second direction, and the heat exchanger is longer in the second direction than in the first direction; The secondary side flow path includes two water pumps, which are located on one side of the heat exchanger in the first direction, and the outlet pipes of the two water pumps cross the top of the heat exchanger and extend to the secondary side outlet of the housing in the first direction; The primary flow path is located on the other side of the heat exchanger in the first direction.

2. The liquid-cooled heat exchanger according to claim 1, wherein, The primary side inlet and primary side outlet of the heat exchanger are arranged at the first flow path connection surface in the second direction, and are arranged opposite to each other in the second direction; The secondary side inlet of the heat exchanger is arranged on the first flow path connection surface, and the secondary side outlet of the heat exchanger is arranged on the second flow path connection surface in the second direction. The secondary side inlet and the secondary side outlet of the heat exchanger are arranged diagonally.

3. The liquid-cooled heat exchanger according to claim 2, wherein, The secondary inlet of the heat exchanger is located above the primary outlet of the heat exchanger.

4. The liquid-cooled heat exchanger according to claim 2 or 3, wherein, The primary inlet and primary outlet of the housing are located on the same side as the primary outlet of the heat exchanger in the second direction; The secondary side inlet of the box is located on the other side of the second direction, and the secondary side outlet of the box is located between the secondary side inlet and the primary side inlet of the box.

5. The liquid-cooled heat exchanger according to claim 1, wherein, The two water pumps are arranged in the first direction.

6. The liquid-cooled heat exchanger according to claim 1 or 5, wherein, The outlet pipes of the two water pumps are straight pipes.

7. The liquid-cooled heat exchanger according to claim 1, wherein, The secondary side flow path includes a water tank, which is connected to the secondary side outlet of the heat exchanger in the first direction and to the inlet pipes of the two water pumps in the second direction.

8. The liquid-cooled heat exchanger according to claim 1, wherein, The secondary flow path includes a check valve, which is arranged between the outlet pipes of the two water pumps and the secondary outlet of the tank.

9. The liquid-cooled heat exchanger according to claim 8, wherein, The check valve is an integrated check valve with two inlets and one outlet. The two inlets of the check valve are respectively connected to the outlet pipelines of the two water pumps, and the single outlet of the check valve is connected to the secondary outlet of the housing.

10. The liquid-cooled heat exchanger according to claim 1, wherein, It also includes a control unit, which is placed in the receiving area and is located on the side of the two water pumps away from the heat exchanger in the first direction.

11. The liquid-cooled heat exchanger according to claim 10, wherein, The control unit has an interactive device arranged in the second direction.

12. The liquid-cooled heat exchanger according to claim 1, wherein, It also includes a power module, which is placed in the receiving area and is located on the side of the two water pumps away from the heat exchanger in the first direction.

13. The liquid-cooled heat exchanger according to claim 1, wherein, The coolant flowing in through the primary side flow path has a higher temperature than the coolant flowing in through the secondary side flow path, and the two exchange heat within the heat exchanger.

14. The liquid-cooled heat exchanger according to claim 1, wherein, The liquid-cooled heat exchanger is a CDU.

15. The liquid-cooled heat exchanger according to claim 14, wherein, The liquid-cooled heat exchanger is a 4U rack-mounted CDU.

16. The liquid-cooled heat exchanger according to claim 14 or 15, wherein, The volume of a single water pump is no more than 1L.

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