Hybrid cooling system and method incorporated into a hermetic rack for information technology equipment

Abstract

The present patent application relates to a hybrid cooling system and method (1) incorporated into a hermetic rack (2) for information technology equipment, designed to cool high-performance electronic components, such as CPUs, GPUs and network interface cards. The hybrid cooling system (1) uses both air and liquid to maintain the optimum temperature of the components, comprising a thermal conditioning system (3) that includes a turbine (4), a radiator (5), a cold air deflector (6) and a water collector (7). The hybrid cooling system (1) is further provided with hot (8) and cold (9) manifold headers, connected to heat sinks (H) and distributed by means of a distribution pump (14) and a tank (15). Control is performed by a control board (18), monitored by a monitoring board (19), which uses level sensors (20), a set of temperature sensors (21), a flow sensor (22) and hybrid temperature and humidity sensors (23).

Description

[0001] Hybrid cooling system and process incorporated into a hermetically sealed rack for information technology equipment.

[0002] BRIEF PRESENTATION

[0003]

[0001] This patent application relates to a hybrid cooling system and process incorporated into a hermetically sealed rack for information technology equipment. The inventive concept of the system stands out for combining a liquid and air cooling system, integrated into a hermetically sealed rack, specifically designed to cool high-performance components such as CPUs, GPUs, and network cards in IT environments. The present invention is equipped with a thermal conditioning system composed of a turbine, radiator, cold air deflectors, and a water collector, in addition to including advanced control and monitoring systems such as level, temperature, and flow sensors, all controlled by a control board and monitored by a specific board.In this way, the present invention promotes effective and stable cooling by ensuring the maintenance of ideal temperatures for critical components, while simultaneously controlling the internal humidity of the hermetic rack, thus providing a safe and efficient environment for IT equipment. The main advantages of the system include superior thermal efficiency, the integration of two cooling systems in a single hermetic environment, and the automated control of temperature and humidity parameters to ensure stability and extend the lifespan of electronic components.

[0004] FIELD OF THE INVENTION

[0005]

[0002] The invention described in this patent application is geared towards the information and communication technology sector, especially sectors that require robust, efficient, and compact solutions for data processing and storage. The invention can be applied in various industries that demand processing, storage, and technology, without the need for a data center infrastructure, such as manufacturing, telecommunications, finance, healthcare, and scientific research industries. BACKGROUND OF THE INVENTION

[0003] It is known to those skilled in the art that DLC (Direct Liquid Cooling) systems are widely used. They are called "Water Cooling" for domestic use and, more recently, have gained space in the business environment.These conventional systems comprise the following components: a heat sink (heatsink or cold plate) positioned over the chip to absorb heat, where cold liquid circulates through the heat sink, performing heat exchange and returning heated to the cooling unit. This unit can be a radiator, chiller, or plate heat exchanger, where heat is transferred to the environment through ventilation. Liquid circulation is maintained by a specific pump. Additionally, ambient air cooling is usually performed by a separate air conditioning system.

[0006] PROBLEM TO BE SOLVED

[0007]

[0004] However, conventional cooling systems have several technical limitations, such as the dependence on a precision air conditioning system for cooling ambient air, requiring the maintenance of hot and cold air corridors for air circulation within data centers. For processors that demand greater cooling capacity, an additional system based on radiators is used, where ambient air cools a liquid that circulates through the heatsinks. In the conventional method, the air is cooled first, and then this cooled air is used to cool the liquid that goes to the heatsinks. Therefore, conventional systems face challenges in high-density environments, where the heat generated by IT components is substantial. Nevertheless, ASHRAE studies indicate that, for processors with a TDP (Thermal Design Power) greater than 350 watts, liquid cooling technology is the most efficient.Currently, we are known to be in the fifth generation of processors, with TDPs that can reach 480 watts, which represents a critical challenge for energy efficiency. The ability of conventional systems to maintain adequate temperatures and ensure optimal processor performance is limited, resulting in higher energy demands and increased operating costs. Maintaining stable temperature and humidity conditions in conventional racks is challenging, especially in environments with varying loads and operations. The installation of IT equipment generally requires substantial additional infrastructure, including separate cooling, power, and connectivity systems. Furthermore, many IT solutions are designed for specific applications and may not be easily adaptable to different industries or environments, requiring complex maintenance and regular interventions to ensure optimal operation.

[0008] CURRENT STATE OF THE ART

[0009]

[0005] It is known from the current state of the art that document US10136551, published on 11 / 20 / 2018, describes a method for cooling a computer server with a plurality of server modules housed in a server rack, the method comprising: circulating a first coolant through a first liquid cooling loop positioned in a first server module, the first liquid cooling loop comprising: a first cold plate sized to thermally couple to a portion of the first server module; a first hot plate; and a first plurality of ducts to circulate the first coolant through the first cold plate and the first hot plate; transferring the heat generated by the first server module to the first coolant through the first cold plate and transferring the heat in the first coolant to the first hot plate;circulating a second coolant through a second liquid cooling loop positioned in a second server module, the second liquid cooling loop comprising: a second cold plate sized to thermally couple to a portion of the server module; a second hot plate; and a second plurality of conduits for circulating the second coolant through the second cold plate and the second hot plate; transferring the heat generated by the second server module to the second coolant through the second cold plate and transferring the heat in the second coolant to the second hot plate; circulating a third coolant through a rack liquid cooling loop, the rack liquid cooling loop comprising: a third cold plate that thermally matches the first hot plate; a fourth cold plate that thermally mates to the second hot plate; a cooling unit;and a third plurality of conduits to circulate the third coolant through the third cold plate, the fourth cold plate and the cooling unit; wherein the third cold plate and the fourth cold plate are positioned externally to the first server module and the second server module; transferring heat from the first hot plate and the second hot plate to the third coolant through the third cold plate and the fourth cold plate, wherein the heat is discharged from the third coolant by the cooling unit.

[0010]

[0006] Document US9907206, published on 2018 / 27 / 2018, describes a cooling system for a computer rack to house at least one first server module and a second server module, the cooling system comprising: a first module liquid cooling loop, comprising: a first cold plate sized to thermally couple to a portion of the first server module; a first hot plate; and a first plurality of ducts to circulate a first coolant through the first cold plate and the first hot plate; a second module liquid cooling loop, comprising: a second cold plate sized to thermally couple to a portion of the second server module; a second hot plate; and a second plurality of ducts to circulate a second coolant through the second cold plate and the second hot plate;A rack fluid cooling circuit comprising: a third cold plate that thermally matches the first hot plate; a fourth cold plate that thermally matches the second hot plate; a cooling unit; and a third plurality of ducts for circulating a third coolant through the third cold plate, the fourth cold plate, and the cooling unit; wherein the third cold plate and the fourth cold plate are positioned externally to the first server module and the second server module, respectively.

[0011]

[0007] The present invention differs from documents US10136551 and US9907206 in that it features a hybrid cooling system incorporated into a hermetically sealed rack, intended for cooling information technology (IT) equipment such as CPUs, GPUs, and network cards, using both liquid and air to control the temperature and humidity within the rack. In document US10136551, the described cooling method uses a closed-loop system with hot and cold plates for heat transfer, where cooling is exclusively performed by means of liquid heat exchangers. Similarly, document US9907206 describes a server module cooling system that also relies on independent liquid cooling loops for each module.However, the innovation of the present application lies in the combination of a hybrid cooling system that uses both air and liquid in a hermetically sealed rack, including elements such as a turbine, radiator, and cold air deflectors, as well as manifolds for distributing the coolant. The present system efficiently removes heat from the rack environment and internal components, integrating temperature, level, and flow sensors for continuous monitoring. Furthermore, the present invention includes automated humidity control, which is not addressed in the cited documents.

[0012] OBJECTIVES OF THE INVENTION

[0013]

[0008] The objective of the present invention is to provide a hybrid cooling system and process incorporated into a hermetically sealed rack of information technology (IT) equipment, capable of maintaining the ideal temperature of high-performance electronic components, such as CPUs, GPUs and network cards, through an efficient system that combines liquid and air cooling.

[0014]

[0009] It is also an objective of the present invention to ensure the effective dissipation of heat generated by the internal components of the hermetic rack, by means of an integrated system of sensors and automated controls that continuously monitor the flow, temperature and level of coolant.

[0015]

[0010] Another objective of the present invention is to control and maintain the internal humidity of the hermetic rack within ideal parameters, preventing the formation of condensation and ensuring the preservation of electronic equipment.

[0016]

[0011] Furthermore, the present invention aims to provide a cooling solution that maximizes energy efficiency, extends the lifespan of IT components, minimizes thermal failures, and ensures the operational stability and safety of equipment.

[0012] Finally, the present invention aims to enable remote control and real-time visualization of the system's operational parameters through a monitoring interface that optimizes the management and operation of the cooling system.

[0017] OF THE INVENTION

[0018]

[0013] The present invention relates to the technical field of cooling for information technology (IT) equipment, more specifically to a hybrid cooling system and process incorporated in a hermetic rack. This system is designed to solve the technical problem of heat dissipation in high-performance electronic components, such as CPUs, GPUs, and network cards, maintaining the ideal temperature and controlling ambient humidity. The present invention comprises a hybrid cooling system that uses both liquids and air to condition the environment within the hermetic rack. The system includes a turbine, radiator, cold air deflectors, hot and cold manifold flutes, distribution pumps, and temperature, level, and flow sensors, all controlled by a control board and continuously monitored by a monitoring board.This innovative solution provides efficient cooling, precise temperature and humidity control, and a stable environment for the operation of IT equipment, extending its lifespan and preventing thermal failures.

[0019] ADVANTAGES OF THE INVENTION

[0020]

[0014] The present invention offers the following advantages: Provides an efficient cooling system for high-performance electronic components, using both liquid and air; Maintains the ideal temperature of the internal components of a hermetic rack, ensuring effective heat dissipation; Ensures precise humidity control within the hermetic rack, preventing condensation and preserving electronic equipment; Incorporates advanced temperature, flow, and level sensors, which allow continuous monitoring of the cooling system; Integrates an automated control and monitoring system that optimizes system operation and prevents thermal failures; Ensures the stability of the thermal environment and the operational safety of IT electronic components; Allows remote visualization and adjustment of operational parameters in real time, through an integrated monitoring interface;It increases the energy efficiency of the refrigeration system, reducing energy consumption and extending the lifespan of the components.

[0021] DESCRIPTION OF THE FIGURES

[0022]

[0015] The following figures are presented to better explain the patent application in an illustrative and non-limiting manner:

[0023]

[0016] Fig. 1: shows a side cutaway view of the airtight rack, showing the cold air deflector, heated liquid return on the radiator, manifold, cold liquid outlet to the radiator, radiator, turbine, system water collector, server motherboard with 2 CPUs, heatsink, GPU card and data storage system;

[0024]

[0017] Fig. 2: shows a side cutaway view of the airtight rack, illustrating the airflow and heat exchange in the system, with hot air rising and being sucked in by the turbine, condensation and collection of water, and cooled air forced downwards;

[0025]

[0018] Fig. 3: shows a side perspective view of the hermetic rack, showing the direct liquid heat exchange system, with hot liquid return and cold liquid outlet;

[0019] Fig. 4: shows a side view of the air conditioning unit and water collector;

[0026]

[0020] Fig. 5: shows the translucent perspective view of the air conditioning unit;

[0027]

[0021] Fig. 6: shows an inverted perspective view of the air conditioning unit, illustrating the flow of hot and cold air in the system;

[0028]

[0022] Fig. 7: shows a perspective view of the hybrid refrigeration system;

[0029]

[0023] Fig. 8: shows an exploded perspective view of the heatsinks;

[0030]

[0024] Fig. 9: illustrates the control process diagram of the hybrid refrigeration system;

[0031]

[0025] Fig. 10: shows the control process diagram of the hybrid refrigeration system, showing the interaction between the monitoring board, the flow, temperature, and level sensors, and the drive of the compressor and distribution pumps;

[0026] Fig. 11: illustrates the monitoring process diagram of the hybrid refrigeration system.

[0032] DETAILED DESCRIPTION OF THE INVENTION

[0033]

[0027] The HYBRID COOLING SYSTEM AND PROCESS INCORPORATED IN A HERMETIC RACK FOR INFORMATION TECHNOLOGY EQUIPMENT consists of a hybrid cooling system (1) incorporated in a hermetic rack (2), designed to cool information technology (IT) equipment using both liquid and air, aiming to maintain the ideal temperature of high-performance electronic components, such as CPUs, GPUs, and network cards. The hybrid cooling system (1) is composed of a liquid and air cooling system formed by a thermal conditioning system (3) configured by a turbine (4), a radiator (5), a cold air deflector (6), and a water collector (7). Additionally, the hybrid cooling system (1) includes a hot manifold rail (8) and a cold manifold rail (9) connected to heatsinks (H), as well as having distribution pumps (14) and a tank (15).

[0034]

[0028] The hybrid refrigeration system (1) also includes a control board (18) and a monitoring board (19), and also has a set of temperature sensors (21), a level sensor (20), a flow sensor (22) and hybrid temperature and humidity sensors (23) and a flow sensor (24).

[0035]

[0029] The hybrid refrigeration system (1) also works in conjunction with a conventional refrigeration system consisting of a cooling and distribution unit (U) equipped with a compressor (13), a dryer filter (S), a heat exchanger (12), an expansion valve (16) and a condenser (17).

[0036]

[0030] In more detail, the hybrid refrigeration system (1) operates from the conventional cooling and distribution unit (U), with the compressor (13) responsible for compressing the refrigerant gas, increasing its pressure and temperature. Then, the pressurized refrigerant gas is conducted to the heat exchanger (12) (condenser), where heat exchange with the environment causes the gas to condense and transform into liquid. After this stage, the refrigerant liquid passes through the dryer filter (S), which removes any moisture particles. Finally, the refrigerant liquid is released at the expansion valve (16), where it expands and consequently decreases in pressure and temperature, restarting the refrigeration cycle.

[0037]

[0031] After initial activation by the conventional cooling system, the hybrid cooling system (1) starts operating in its innovative configuration, in which the liquid cooling circuit is activated, initiating the cooling process from the coolant storage tank (15), where the cooled coolant is stored. Then, the coolant is propelled by the distribution pump (14) (N+1), which distributes the coolant to the cold manifold rail (9), which distributes the liquid to the heatsinks (H) of the components, such as CPUs, GPUs and network cards.

[0038]

[0032] In this way, the heat contained inside the hermetic rack (2) and the CPUs, GPUs and network cards is removed with the hot air being sucked in by the turbine (4) of the thermal conditioning system (3) and forced to pass through the radiator (5), where the heat is removed by the coolant. The air is cooled before being redirected to the components by means of the cold air deflectors (6). Subsequently, the coolant, now cooled, is in the hot phase, and returns to the hot manifold rail (8), while the coolant, upon exiting the hot manifold rail (8), goes to the heat exchanger (12), where the heat is removed by the refrigerant gas and then returns to the tank (15), so that the cycle repeats. Meanwhile, to maintain the relative humidity between 30% and 60%, a humidifier (not shown) operates in the system.

[0039]

[0033] The hybrid cooling system (1) is controlled by the control board (18) and monitored by a monitoring board (19).

[0040]

[0034] The control board (18) controls the drive of the compressor (13), the distribution pump (14) and the condenser (17).

[0041]

[0035] The monitoring board (19), in addition to monitoring the level sensor (20) located in the tank (15), also monitors the temperature of the tank (15) by means of a primary temperature sensor (21 A). Furthermore, the monitoring board (19) monitors the temperature of the liquid at the inlet of the hermetic rack (2) by means of a secondary temperature sensor (21 B), also monitors the temperature of the liquid exiting the hermetic rack (2) by means of a tertiary temperature sensor (21 C) and a quaternary temperature sensor (21 D), and also monitors the liquid flow rate by means of a flow sensor (22). In addition to monitoring the temperature and flow rate of the liquid, the monitoring board (19) also monitors the monitoring cycle of the compressor (13).

[0042]

[0036] Nevertheless, in the hermetic rack (2) the monitoring board (19) performs the monitoring of the temperature and relative humidity of the air in the internal environment of said hermetic rack (2).

[0043]

[0037] Furthermore, the monitoring board (19) has relays (not shown) to control the opening and closing of doors, as well as humidification control (not shown). In addition, the monitoring board (19) can also perform CPU resets.

[0044]

[0038] In due course, the monitoring board (19) has hybrid temperature and humidity sensors (23), which are located inside the hermetic rack (2) in order to send data to the control board (18), so that the internal temperature of said hermetic rack (2) is maintained within the ideal operating parameters of the system.

[0039] The control board (18) has a flow sensor (24), which ensures that the coolant is flowing in the system and thus removing heat from the CPUs, GPUs and network cards, in order to guarantee the ideal operation of said hybrid cooling system (1).

[0045] OF CONTROL AND MONITORING PROCESSES

[0046]

[0040] Fig. 9 illustrates the control process diagram of the hybrid refrigeration system (1). The process begins with the reception of data by the monitoring board (19). First, the hybrid refrigeration system (1) verifies the existence of flow by means of the flow sensor (24). This flow verification occurs continuously throughout the operation in order to ensure that the refrigerant is circulating properly. Then, the refrigerant temperature is measured by the primary temperature sensor (21 A), located in the tank (15), by the secondary temperature sensor (21 B), located at the inlet of the hermetic rack (2), and by the tertiary temperature sensor (21 C) located at the outlet of the hermetic rack (2), in addition to the quaternary temperature sensor (21 D).If the temperature measured by any of these sensors exceeds the preset value, the compressor (13) is activated; otherwise, it remains off, and the hybrid refrigeration system (1) operates passively, using the natural cooling of the liquid.

[0047]

[0041] After checking the flow and temperature, the fluid level in the tank (15) is analyzed by the level sensor (20). If the level is below the acceptable minimum, the control system triggers a leak alarm, notifying the operators of the need for intervention. In response to this alarm, the system can take one of two measures: reduce operation until the problem is resolved, or completely shut down the distribution pump (14) and the compressor (13) in order to prevent further damage.

[0048]

[0042] In parallel, it is checked whether the distribution pump (14) is switched on and operating correctly. If there is refrigerant flow, the compressor (13) continues to operate to maintain refrigeration operation. Otherwise, both the distribution pump (14) and the compressor (13) are switched off automatically, and the hybrid refrigeration system (1) enters standby mode until the flow is restored. Throughout the operation, the control board (18) continuously adjusts the operating parameters based on information received from the flow sensor (24), temperature sensors (21 A, 21 B, 21 C and 21 D) and the level sensor (20), and ensures the stability of the thermal environment inside the hermetic rack (2).

[0049]

[0043] Fig. 11 illustrates the monitoring process diagram for the hybrid refrigeration system (1). This process involves the continuous collection of temperature and humidity data inside and outside the hermetic rack (2), using hybrid temperature and humidity sensors (23). These sensors monitor both the internal and external environment, sending the data to the monitoring board (19). In addition, the monitoring board (19) also receives information from a power meter (not shown) that monitors the power factor, current consumption and supply voltage of the system.

[0050]

[0044] The information collected by the sensors is processed by the monitoring board (19) and sent to a dashboard via communication protocol (specified according to standard X or Y), where operators can view the operational status of the system in real time. Based on the data received, commands can be sent back to adjust the system operation, ensuring refrigeration stability and energy efficiency. These commands include adjustments to the compressor (13), distribution pumps (14) and condenser (17), as needed to maintain temperature and humidity within ideal parameters.

[0051]

[0045] The continuous monitoring process allows remote control of the system, which ensures that any deviations from normal parameters are corrected immediately. The continuous monitoring and control cycle ensures that the hybrid cooling system (1) operates efficiently, removing heat from the IT components inside the hermetic rack (2), aiming to maintain relative humidity between 30% and 60%, as required for the indoor environment.

Claims

CLAIMS 1) HYBRID COOLING SYSTEM INCORPORATED IN A HERMETIC RACK FOR INFORMATION TECHNOLOGY EQUIPMENT, consists of a conventional cooling system composed of a cooling and distribution unit (U), equipped with a compressor (13), a heat exchanger (12), a dryer filter (S), an expansion valve (16) and a condenser (17), also having heatsinks (H) applied to CPUs, GPUs and network cards, characterized by being a hybrid cooling system (1) incorporated in a hermetic rack (2), whose liquid and air hybrid cooling system (1) is formed by a thermal conditioning system (3) composed of a turbine (4), a radiator (5), a cold air deflector (6), a water collector (7);Furthermore, the hybrid cooling system (1) comprises a hot manifold rail (8) and a cold manifold rail (9) connected to heatsinks (H), having a distribution pump (14), a tank (15), a control board (18) and a monitoring board (19); wherein, the distribution pump (14) distributes the coolant to the heatsinks (H) and the radiator (5); wherein the turbine (4) forces the hot air to pass through the radiator (5) for cooling, redirecting the cold air to the components of the hermetic rack (2) by means of the cold air deflectors (6); wherein the heated coolant returns to the hot manifold rail (8) and subsequently to the heat exchanger (12) for heat removal, before returning to the tank (15) to restart the cycle. 2) A HYBRID REFRIGERATION SYSTEM INCORPORATED IN A HERMETIC RACK FOR INFORMATION TECHNOLOGY EQUIPMENT, according to claim 1, is characterized by including hybrid temperature and humidity sensors (23) inside the hermetic rack (2), which send data to the control board (18) to adjust the internal temperature and humidity. 3) A HYBRID REFRIGERATION SYSTEM INCORPORATED IN A HERMETIC RACK FOR INFORMATION TECHNOLOGY EQUIPMENT, according to claim 1, is characterized by the monitoring board (19) monitoring the temperature of the refrigerant liquid in the tank (15) by means of a set of temperature sensors (21) consisting of a primary temperature sensor (21A) and controlling the operations of the distribution pumps (14) and the compressor (13) based on the sensor readings. 4) HYBRID REFRIGERATION SYSTEM CONTROL PROCESS, whereby the hybrid refrigeration system (1) of claim 1 is characterized by including the following steps: - Receive refrigerant flow data via the flow sensor (24) and continuously check if the flow is adequate; - Measure the refrigerant temperature in the tank (15) using the primary temperature sensor (21 A) and activate the compressor (13) if the temperature exceeds a predefined value, or operate the system passively if the temperature is within the parameters; - Monitor the refrigerant temperature at the inlet of the hermetic rack (2) by means of the secondary temperature sensor (21 B) and at the outlet of the hermetic rack (2) by means of the tertiary temperature sensor (21 C) and quaternary temperature sensor (21 D), adjusting the operation of the distribution pump (14) and compressor (13) as necessary to maintain adequate cooling; - Monitor the fluid level in the tank (15) using the level sensor (20) and, in case of low levels, trigger a leak alarm and automatically shut down the distribution pump (14) and the compressor (13) to prevent further damage; - Continuously adjust the system's operating parameters based on sensor information to ensure thermal stability within the hermetic rack (2), and automatically restart the distribution pump (14) and compressor (13) when refrigerant flow is restored. 5) HYBRID REFRIGERATION SYSTEM CONTROL PROCESS, according to claim 4, characterized by including continuous monitoring of the temperature and humidity of the internal environment of the hermetic rack (2) by means of hybrid temperature and humidity sensors (23). 6) HYBRID REFRIGERATION SYSTEM CONTROL PROCESS, according to claim 4, characterized by including the transmission of data collected by the level sensor (20), flow sensor (22), hybrid temperature sensors and humidity (23) and flow sensor (24) to a dashboard via communication protocol, allowing remote monitoring and execution of adjustment commands, including adjustments to the compressor (13), distribution pump (14) and condenser (17) to ensure operational and energy efficiency of the hybrid refrigeration system (1).

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