Flat panel design for water and air cooling

Abstract

A flat panel for water or air cooling includes end shrouds, potting frames coupled to the end shrouds, and end caps over the potting frames. A hollow fiber mat is wound around an inner frame between the potting frames. The ends of fibers in the hollow fiber mat are open at the potting frames to provide for flow of water between ports on the potting frames. When the panel is in use, water is pumped into one port and enters the ends of the fibers in the mat at one of the potting frames. The water flows through the fibers of the mat causing evaporation and producing chilled water the port in the other potting frame. A fan can be used to direct air across the hollow fiber mat to enhance the evaporation and cooling effect.

Description

PA103084W002FLAT PANEL DESIGN FOR WATER AND AIR COOLINGBACKGROUND

[0001] Data centers, which house large volumes of servers and networking equipment, require efficient cooling systems to manage the significant heat generated by their operations. Water chilling using evaporative cooling phenomena is an effective and energy-efficient method for maintaining optimal temperatures in data centers. Evaporative cooling is particularly suitable for large data centers where high efficiency and cost-effectiveness are crucial. In addition, other application areas include HVAC systems, industrial cooling towers, humidification, and dehumidification.

[0002] The primary cooling medium, chilled water, is circulated through a closed-loop system, absorbing heat from the data center equipment. The heated water from the data center is pumped to cooling towers, where evaporative cooling is employed to dissipate the heat. Heat exchangers facilitate the transfer of heat from the data center equipment to the chilled water, and subsequently from the chilled water to the cooling tower water. Within the cooling towers, spray nozzles disperse the bulk water flow into a fine spray, maximizing the surface area for latent heat exchange between the water and air. Some systems use porous media to further increase the surface area for evaporation. Fans or natural draft mechanisms draw or force air through the cooling towers. The air interacts with the water, causing a portion of it to evaporate, which cools the remaining water. During evaporation, sensible heat from the water is converted into latent heat, effectively lowering the water temperature. This cooled water is then recirculated back to absorb more heat from the data center.

[0003] Evaporative cooling is efficient, requiring less energy than traditional air conditioning systems to achieve the same cooling effect. The high heat transfer rates associated with evaporative cooling make it effective for handling the large thermal loads in data centers. Lower energy consumption translates to reduced operating costs, which is critical for the cost-intensive operations of data centers. Utilizing evaporative cooling reduces the overall carbon footprint of data centers by lowering energy requirements and reliance on refrigerants.

[0004] Some of the challenges include continuous operation that requires a steady supply of makeup water to compensate for the evaporated water. Proper water treatment is essential to prevent scaling, corrosion, and biological growth in the cooling towers and associated piping. With the advent of Artificial Intelligence (Al) and Machine Learning (ML), the demand for high heat flux removal and cooling has risen dramatically.SUMMARY

[0005] A flat panel for water or air cooling includes end shrouds, potting frames coupled to the end shrouds, and end caps over the potting frames. A hollow fiber mat is wound around an inner frame between the first and second potting frames. The ends of fibers in the hollow fiber mat are open at the potting frames to provide for flow of a liquid between ports on the potting frames.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1A is a perspective view of an assembled molded design of a flat panel.

[0007] FIG. IB is a perspective view of an assembled machined design of a flat panel.

[0008] FIG. 2A is a perspective view of a flat panel sub-assembly for the molded design.

[0009] FIG. 2B is a diagram of an inner frame for the flat panel sub-assembly.

[0010] FIG. 2C is a diagram of another inner frame for the flat panel sub-assembly.

[0011] FIG. 3 is a perspective view of a potting frame and end shroud assembly for the molded design.

[0012] FIGS. 4A and 4B are perspective views of a potting frame for the molded design.

[0013] FIGS. 5A and 5B are perspective views of an end shroud for the molded design.

[0014] FIGS. 6A and 6B are perspective views of an end cap for the molded design.

[0015] FIG. 7 is an exploded view of a flat panel for the machined design.

[0016] FIGS. 8A and 8B are perspective views of a potting frame for the machined design.

[0017] FIG. 9 is a perspective view of an end shroud for the machined design.

[0018] FIGS. 10A and 10B are perspective views of an end cap for the machined design.

[0019] FIG. 11 is a diagram of an air handler with flat panels arranged in parallel.

[0020] FIG. 12 is a diagram of flat panels arranged in a triangular module.

[0021] FIG. 13 is a diagram of flat panels arranged in a square module.

[0022] FIG. 14 is a diagram of flat panels in a V-shaped module.

[0023] FIG. 15 is a diagram of flat panels in a parallel module.

[0024] FIG. 16 is a diagram of modules of multiple flat panels in an array of V-shaped modules.

[0025] FIG. 17 is a diagram of modules of multiple flat panels in a square array.

[0026] FIG. 18 is a diagram of modules of multiple flat panels in a triangular shaped array.DETAILED DESCRIPTION

[0027] The flat panel described herein is a design where the wounded hollow fiber mat can be assembled, and the panel can be used for both water- and air-cooling applications. This design is an effective way to flow water through the hollow fibers and allow the air flow around the fibers to either cool the water or air through evaporation of water. The advantage of this design is simpler manufacturing process, three molded or machined parts and easy implementation in applications. The flat panel design can be arranged in an air handler or other systems as modules in a parallel configuration, or in the shape of a triangle, square, v- shaped or any polygon. The designs covered herein are both molded and machined part designs.

[0028] Examples of evaporative cooling systems and modules are disclosed in PCT Application Publication Number WO 2023 / 037287, which is incorporated herein by reference as if fully set forth.

[0029] FIGS. 1 A and IB are perspective view, respectively, of an assembled molded design of a flat panel and an assembled machined design of a flat panel. Molded flat panel 10 includes a hollow fiber mat 12, potting frames 14, end shrouds 16, end caps 18, an inlet port 20, and an outlet port 22. Machined flat panel 30 includes a hollow fiber mat 32, potting frames 34, end shrouds 36, end caps 38, an inlet port 40, and an outlet port 42.

[0030] Molded Design:

[0031] The flat panel design includes three parts: potting frame 14, end shroud 16, and end cap 18.

[0032] Potting Frame 14. The potting frame 14 is where the wounded hollow fiber mat is potted. FIG. 2A is a perspective view of a flat panel sub-assembly for the molded design showing the potted fiber mat in the frame, and FIG. 2B is a diagram of an inner frame for the flat panel sub-assembly having horizontal bars 44 and vertical bars 46 that can be glued or otherwise affixed together. FIG. 2C is a diagram of another inner frame, in an optional configuration, for the flat panel sub-assembly having horizontal bars 45 and vertical bars 47 that can be glued or otherwise affixed together. The bars are horizontal and vertical when panel 10 is positioned vertically for use. FIGS. 4A and 4B are perspective views of a potting frame for the molded design.

[0033] The hollow fiber mat is wound around the inner frame based upon the number of layers required for a particular application with sufficient tension to prevent unwrapping of the mat.

[0034] The design features which are in the inner surface are used for injecting the potting material when the mat is inserted into the frame, and semi-circular features on both ends of the frame are used for the end shroud to have an interference fit. A hole opens up at 90 degrees that is used for entry and exit of water to and from the panel. The ribs that are on both sides of the potting frame provides structural integrity, reducing the amount of material needed for molding the potting frame.

[0035] End Shroud 16. The end shroud 16 provides structural support to the flat panel on both sides and keeps both the potting frame and the wounded hollow fiber in place. The horizontal ribs that run through the part provide structural strength to the shroud. The vertical rib is used for sealing to the hollow fiber and reducing the leakage of air through the flat panel. Optionally, foam or an adhesive can also be used for sealing the molded flat panel. FIG. 3 is a perspective view of potting frame 14 and end shroud 16 subassembly for the molded design. FIGS. 5A and 5B are perspective views of end shroud 14 for the molded design. FIG. 5A illustrates the features of end shroud 16 which slide into potting frame 14 and provide an interference fit. Once the hollow fiber mat is potted in the potting frame 14 of the sub-assembly (FIG. 3), the fibers of the hollow fiber mat can be opened through a cutting process where the fibers are machined off in potting frame 14.

[0036] End cap 18. FIGS. 6A and 6B are perspective views of end cap 18 for the molded design. The end cap 18 is hermetically sealed on potting frame 14 using structural adhesive or any bonding technique such as ultrasonic, hot-plate or laser welding. The water that comes from the fibers are collected in the end cap and the slot feature that runs all around the parts is used as a reservoir for the adhesive and provides a continuous bond between the potting frame and end cap. This feature can also be modified as an energy director for ultrasonics or other bonding techniques. The two pins on the end cap are used for alignment of end cap 18 with the potting frame 14. End cap 18 can be glued or otherwise affixed to potting frame 14 after the fibers have been opened as described above.

[0037] When flat panel 10 is in use, water or other liquid is pumped into inlet port 20 and enters the ends of the fibers in mat 12 potted in potting frame 14. The water flows through the fibers of the mat causingevaporation and producing chilled water at outlet port 22. A fan can alternatively be used to direct air across the hollow fiber mat to enhance the evaporation and cooling effect.

[0038] Machined Design:

[0039] The flat panel design can also be formed through machined parts by modifying the features. This design can be readily manufactured using CNC machining. FIG. 7 is an exploded view of a flat panel for the machined design and having the components identified with respect to FIG. IB.

[0040] Potting Frame 34. The machined potting frame 34 design is similar to the molded design without the ribs, and four holes provided at four comers can be used for assembling to the end shroud with dovel pins. FIGS. 8A and 8B are perspective views of potting frame 34 for the machined design.

[0041] End Shroud 36. The end shroud 36 design is modified for the ease of machining by removing all the rib features, and the two holes at the top and bottom of the parts are used for assembling with the potting frame using the dovel pins. FIG. 9 is a perspective view of end shroud 36 for the machined design.

[0042] End cap 38. The end cap 38 design is modified further for the ease of machining by removing all the features and modifying the glue reservoir. FIGS. 10A and 10B are perspective views of end cap 38 for the machined design.

[0043] The components of the machined design can be assembled as described above for the molded design. Foam or an adhesive can optionally be used for sealing the machined flat panel.

[0044] When flat panel 30 is in use, water or other liquid is pumped into inlet port 40 and enters the ends of the fibers in mat 32 potted in potting frame 34. The water flows through the fibers of the mat causing evaporation and producing chilled water at outlet port 42. A fan can alternatively be used to direct air across the hollow fiber mat to enhance the evaporation and cooling effect.

[0045] The following are exemplary materials and parameters for the flat panels. The potting frame, shroud, and end caps of the molded design can be composed of plastic or other moldable materials. The potting frame, shroud, and end caps of the machined design can be composed of plastic or other machinable materials. The inner frame can be composed of plastic rods and / or bars. The inlet and outlet ports can be composed of a metal material and configured for attachment to a water source.

[0046] The following are exemplary parameters for the hollow fiber mat or membrane: a pore size of 0.01-0.2 microns and preferred of 0.03-0.04 microns; a porosity of 25%-80%; a wall thickness (single layer) of 15-75 microns and preferred of 25-50 microns; and a knitting density of 20-60 fibers per inch and preferred of 35-53 fibers per inch. An example of a hollow fiber mat or membrane is disclosed in U.S. Patent No. 9,541,302.

[0047] Flat Panel Configurations:

[0048] The flexibility of having a flat panel design, as shown in FIGS. 1 A and IB, is that it can be arranged in different ways as illustrated in FIGS. 11-18. A flat panel is not limited to these shapes and can also be arranged as a polygon, hexagon, octagon, and other configurations. The solid panels among the flat panels are where the air flow is blocked. Air can enter an inner volume of the modules and then flow across the flat panels and exit out of the module.

[0049] FIG. 11 is a diagram of an air handler 50 with flat panels 52 arranged in parallel. Air handler 50 includes solid panels 51 at a front edge of handler 50 and solid panels 53 as a back edge of handler 50.

[0050] FIG. 12 is a diagram of flat panels 54 arranged in a triangular module with a solid panel 56 on one end.

[0051] FIG. 13 is a diagram of flat panels 58 arranged in a square module with a solid panel 60 on one end.

[0052] FIG. 14 is a diagram of flat panels 62 in a V-shaped module with solid panels 64 between them.

[0053] FIG. 15 is a diagram of flat panels 66 in a parallel module with solid panels 68 between them. This configuration also includes another solid panel at the back of the configuration and between flat panels 66.

[0054] FIG. 16 is a diagram of modules of multiple flat panels in a V-shaped array using the configuration of FIG. 14.

[0055] FIG. 17 is a diagram of modules of multiple flat panels in a square array using the configuration of FIG. 13 with solid panels 70 between modules.

[0056] FIG. 18 is a diagram of modules of multiple flat panels in a triangular shaped array using the configuration of FIG. 12 with a solid panel 72 between them. In this configuration, the center is open underneath solid panel 72 and between the modules of multiple flat panels.

[0057] The arrays shown in FIGS. 16-18 can be used, for example, to fill an air handling unit.

[0058] In the modules and arrays shown in FIGS. 11-18, the panels can be, for example, 19X19 inches, but these modules and arrays can also be made with other dimensions of the panels such as rectangular panels that are 16X8 inches or 8X8 inches, or other dimensions. These modules and arrays can be also made with a combination of different shapes of panels.

[0059] The following are additional exemplary embodiments of flat panels described herein.

[0060] A panel comprising a polypropylene hollow porous fiber membrane material potted using epoxy adhesive on a ABS plastic cap, wherein the fiber mat is oriented vertically for efficient water circulation, wherein the exposed fiber area of a panel is 16 inches X 16 inches, and wherein each panel contains 46 layers of fiber mat, and wherein the delta T obtained for water cooling from two such panels, a module, is between 13 °F- 30°F based on the inlet water and air conditions, and wherein the air flow rate is between 150 - 250 CFM, and wherein the water flow rate is between 0.2 GPM - 0.4 GPM per panel with 101 °F water inlet temperature, and wherein the inlet air temperature is between 95 °F - 115 °F, and wherein the inlet relative humidity is between 15% - 25%.

[0061] The exposed frontal area of the panel can be chosen based on the delta T water cooled, and wherein the exposed frontal area of the panel can be from 8 inches X 8 inches to 16 inches X 24 inches. The layer count can be from 15 to 55. The inlet air temperature can be from 70 °F - 120 °F. The inlet relative humidity of air can be from 10% - 70%. The inlet air flow rate can range from 50 CFM - 900 CFM. The inlet water flow rate can be from 0.2 GPM to 1 GPM per panel. The inlet water temperature can be from 70 °F - 120 °F.

Claims

The invention claimed is:

1. A flat panel for water or air cooling, comprising: a first end shroud; a second end shroud; a first potting frame coupled to the first and second end shrouds; a second potting frame coupled to the first and second end shrouds on a side opposite the first potting frame; a first port on the first potting frame; a second port on the second potting frame; a first end cap over the first potting frame; a second end cap over the second potting frame; and a hollow fiber mat wound around an inner frame between the first and second potting frames, wherein ends of fibers in the hollow fiber mat are open at the first and second potting frames to provide for flow of a liquid between the first and second ports.

2. The flat panel of claim 1, wherein the first and second end shrouds, the first and second potting frames, and the first and second end caps are all composed of a moldable material.

3. The flat panel of claim 1, wherein the first and second end shrouds, the first and second potting frames, and the first and second end caps are all composed of a machinable material.

4. The flat panel of claim 1, wherein the first and second ports are configured to be coupled to a water source.

5. The flat panel of claim 1, wherein the first and second ports are composed of a plastic or metal material.

6. The flat panel of claim 1, wherein the inner frame includes two vertical bars, and two horizontal bars coupled to the two vertical bars.

7. The flat panel of claim 1, wherein the hollow fiber mat is wound multiple times around the inner frame.

8. A system, comprising an air handler with multiple flat panels of claim 1 arranged in parallel.

9. A system, comprising multiple flat panels of claim 1 arranged in a triangular configuration.

10. A system, comprising multiple flat panels of claim 1 arranged in a square configuration.

11. A system, comprising multiple flat panels of claim 1 in a triangular module.

12. A system, comprising multiple flat panels of claim 1 in a square module.

13. A system, comprising modules of multiple flat panels of claim 1 in a V-shaped array.

14. A system, comprising modules of multiple flat panels of claim 1 in a parallel module.

15. A system, comprising modules of multiple flat panels of claim 1 in a triangular shaped array.

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