Method and system for integrating server racks in an immersion cooling system

Abstract

Systems and methods install and remove a rack-mounted server system in an immersion cooling system. The immersion cooling system comprises an internal support structure configured with complementary dimensions to the rack unit of the rack-mounted server system. The rack-mounted server system may be aligned above the internal support structure and lowered into the tank of the immersion cooling system. The internal support structure allows for a plurality of electrical appliances, previously configured and installed in a rack unit, to be installed in an immersion cooling system without the need to individually removing each electrical appliance from the rack unit and reconnecting them in the immersion cooling system.

Description

PATENT Attorney Docket No. 250168PCT IN THE UNITED STATES RECEIVING OFFICE PATENT COOPERATION TREATY (PCT) APPLICATION FORMETHOD AND SYSTEM FOR INTEGRATING SERVER RACKS IN AN IMMERSION COOLING SYSTEMInventor: Mario Conti GarciaPRIORITY CLAIM

[0001] The present application claims priority to United States provisional application Serial No. 63 / 776,641, filed March 24, 2025, titled “Method and System For Integrating Server Racks in an Immersion Cooling System,” which is incorporated herein by reference.BACKGROUND

[0002] In traditional air-cooled server systems, the end customers often hire a server integration service to build a complete rack-mounted server rack solution based on the customer’s hardware and software needs. The customer selects various hardware components (e.g., servers, network infrastructure, power supply units), cooling type (air-cooled or liquid cooled), and software components that the server integration service uses to build the rackmounted server. The integration service uses the selected components and first installs the hardware components into the rack, connects each hardware component, powers up the system, installs the software components, troubleshoots any issues, verifies operability, and packages the fully built rack-mounted server to ship to the customer.

[0003] The customer has many factors to consider when selecting a cooling type. As the computational demand of server systems have increased, so has the heat generation of the hardware components. Immersion cooling is an efficient system for extracting heat from electrical appliances such as rack-mounted servers with a dielectric fluid and can be used as an alternative to conventional air-cooled systems. However, hardware components are usually designed to be cooled by air-cooled systems or direct liquid cooling systems.Immersion cooling requires special configurations that are different than those for servers intended to be cooled with air or direct liquid cooling adding substantial complexity to existing supply chains.

[0004] The build process for an immersion-cooled server solution presents additional complications because immersible hardware components cannot be powered up until they are installed in an immersion cooling tank and connected to the other hardware components in the system. The immersible hardware components are specially configured to be cooled by a 11607743887.5Docket No. 250168PCTdielectric fluid (e.g., coolant) that completely surrounds the heat sensitive components such as CPUs and GPUs. The dielectric fluid extracts heat generated by the heat sensitive components, so they maintain proper operating temperatures. The immersible hardware components do not have traditional fans and even temporary operation outside of an immersion cooling tank can create permanent damage to these components. Once the integration service has completed the build process in the immersion cooling tanks, the immersible hardware components must be disconnected, removed from the dielectric fluid, drained of the dielectric fluid, packaged, and shipped separately to the end customer.

[0005] With traditional air-cooled systems, the end-customer receives a fully built server rack solution that just needs to be powered up and integrated into their data center. However, with the immersion-cooled system, the end-customer receives a disassembled system that still need to be re-assembled and connected in the customer’s immersion cooling system.SUMMARY OF THE INVENTION

[0006] In a general aspect, the present inventions are directed to immersion cooling systems for electronic hardware, particularly rack-mounted server systems used in data centers.Traditional air-cooled systems require complex assembly and integration processes, while immersion cooling offers improved thermal management but presents logistical challenges in installation and shipping. The present invention, in various embodiments, provides an immersion cooling system that includes a tank adapted to immerse a plurality of electrical appliances in a dielectric fluid for efficient heat dissipation. The immersion cooling system also comprises an internal support structure designed to receive and support a rack unit within the tank, ensuring proper positioning and stability. The rack unit houses multiple electrical appliances and is dimensioned to fit within the support structure, facilitating seamless installation and removal.

[0007] This design allows for pre-assembled rack-mounted server systems to be integrated into an immersion cooling environment without requiring individual disassembly and reconfiguration at the customer’s site. The system also improves ease of handling, enhances cooling efficiency, and reduces potential damage during transport and installation. In certain embodiments, the internal support structure provides an interface between standardized rackmounted server systems and immersion cooling infrastructure, enabling interoperability between independently designed rack units and immersion cooling tanks without requiring modification of the rack-mounted server systems. These and other benefits that can be21607743887.5Docket No. 250168PCTrealized through embodiments of the present invention will be apparent from the description that follows.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various embodiments of the present invention are described herein by way of example in connection with the following figures.

[0009] Figure 1 shows an embodiment of an internal support structure of an immersion cooling system, according to various aspects of the present invention.

[0010] Figure 2 shows another embodiment of an internal support structure of an immersion cooling system, according to various aspects of the present invention.

[0011] Figures 3A-3C show a plurality of internal support structures configured to receive various configurations of electrical appliances, according to various aspects of the present invention including the first internal support structure and the second internal support structure.

[0012] Figures 4A-E show the steps for installing and / or removing a rack-mounted server system 106 in an immersion cooling system comprising a first internal support structure, according to various aspects of the present invention.

[0013] Figures 5A-E show the steps for installing and / or removing a rack-mounted server system in an immersion cooling system comprising a second internal support structure, according to various aspects of the present invention. The steps of Figures 4A-E may be repeated with the universal mounting brackets that align with the plurality of guide rails of the internal support structure.DETAILED DESCRIPTION

[0014] Figure 1 shows an embodiment of an internal support structure 102 of an immersion cooling system 100, according to various aspects of the present invention. The immersion cooling system 100 comprises a tank 101 adapted to immerse a rack unit 104 (e.g., rack unit or RU) in a dielectric fluid (e.g., coolant). The immersion cooling system 100 may further comprise a plurality of components including a heat exchanger, one or more pumps, inlet fluid dispersion mechanism (e.g., dielectric fluid inlet at a wall of the tank providing the dielectric fluid into a plenum or manifold which distributes the dielectric fluid into the tank or to specific components), and / or outlet fluid recovery mechanism (e.g., a weir positioned along a surface of the tank that allows heated coolant to flow into a recovery reservoir). The31607743887.5Docket No. 250168PCTimmersion cooling system may be configured in various aspects as disclosed, for example, in U.S. Patent No. 10,405,457, which is herein incorporated by reference in its entirety.

[0015] The internal support structure 102 is configured to receive and support a rackmounted server system 106 that may be lowered into the internal support structure 102. The internal support structure 102 is a load bearing structure configured at slightly larger internal dimensions than the external dimensions of the rack unit 104, or sufficient to accommodate the exterior dimensions within a predetermined tolerance (e.g., + / - 5 mm). The internal support structure 102 may be secured within the interior of the tank 101 to receive the rack unit 104, while the rack unit 104 is a removable structure that allows a plurality of electrical appliances 110 to be mounted in a predetermined structural configuration. The tank 101 may comprise one or more motion or vibration dampers that absorb motion in or around the tank 101. In one example, the tank 101 may be positioned on a base with dampers that are configured to absorb external motion such as vibrations caused by an earthquake. In another example, the tank 101 comprises internal dampers that allow for movement by the internal support structure 102 or the rack unit 104. The internal dampers may be positioned between the tank 101 and the internal support structure 102, or between the internal support structure 102 and the rack unit 104. The motion dampers may be configured to allow for a predetermined amount of motion (e.g., lateral movement, vertical movement) by the internal support structure 102 or rack unit 104 based on spring constants, gas density, polymer density, or liquid viscosity associated with compression elements within the motion dampers.

[0016] The internal support structure 102 may elevate the rack-mounted server system 106 above the bottom of the tank 108, supply and return distribution connections adjacent to the bottom of the tank 108, or position the rack-mounted server over a plenum that disperses the dielectric fluid through the electrical appliances 110 (e.g., rack-mounted servers, network switches, power supply units 118) mounted in the rack-mounted server system 106. In various embodiments, the internal support structure 102 is configured to position the rack unit 104 in a predetermined location relative to the plenum such that openings, channels, or interstitial spaces within the rack-mounted server system 106 are aligned with one or more outlets of the plenum. This alignment may direct dielectric fluid through regions of higher heat density within the rack-mounted server system 106 and promote uniform flow distribution through the plurality of electrical appliances 110. In some embodiments, deviation from the predetermined position may result in reduced cooling efficiency due to flow bypass or non-uniform fluid distribution, thereby making the positioning function of the internal support structure 102 functionally significant. The rack unit 104 of the rack-mounted 41607743887.5Docket No. 250168PCTserver system 106 may be the external structure of the rack-mounted server system 106 and configured without housing or enclosure panels to allow the dielectric coolant to flow to the heat generating components of the electrical appliances mounted in the rack unit 104. The rack unit 104 may be configured with a liquid distribution manifold designed for cold-plate liquid cooling such as the standardized distribution manifold described in Open Compute Project (OCP) Open Rack (OR) Specification version 3.

[0017] The internal dimensions of the internal support structure 102 may be based on an industry standard or trade association specification (e.g., OCP Open Rack Specification) for rack-mounted servers (e.g., electrical appliances 110) as well as proprietary or non-standard dimensions. For example, the industry standards may specify that the server rack must have predefined internal dimensions to support standard U mounted servers. The internal support structure 102 may be configured to position the rack-mounted server system 106 such that standardized features (e.g., busbar 120, power management, cable management), by industry standards, are routed to the reception structure within the immersion cooling system 100. For example, a standardized rack unit may comprise a busbar 120 configured to power rackmounted servers 110 with 48v DC, through a PSU 118 that receives an AC input from above and outputs a 48v DC power source through the busbar 120. The busbar 120 may align with other DC power sources that energize the busbar 120 and provide power for the plurality of electrical appliances 110. When the rack unit is positioned horizontally on its side rather than vertically in a typical data center, the input power and network connection infrastructure 124 may be provided along a first side 112a of the tank, a second side 112b, both. For example, if the immersion cooling system installed with two half rack units, each half rack unit may be connected to a different power and network connection infrastructure on opposite sides of the tank.

[0018] The internal support structure 102 may comprise bottom mounts 112 and top mounts 114, or optionally rails, ledges, saddles, pins, brackets, detents, or other load-bearing structural members configured to position and / or secure the rack unit 104 within the tank 101. The bottom mounts 112 of the internal support structure 102 may comprise a lip (e.g., elevation member) 116 on each bottom mount 112 that extends along the entire bottom edge and is configured to position the rack unit 104 at a predetermined or adjustable height within the tank 101. The lip 116 may be configured at slightly smaller dimensions that the exterior dimensions of the rack-mounted server system 106 and the rack unit 104, such that the rackmounted server system 106 is supported by the internal support structure and does not come in direct contact with the bottom of the tank and / or is positioned over the plenum. The51607743887.5Docket No. 250168PCTinternal support structure 102 may comprise one or more keyed guide rails (e.g. alignment members) that allow the rack-mounted server system 106 to align with specific structural features of the immersion cooling system, such as orifices of the plenum that disperses and distributes dielectric fluid between the electrical appliances or a fluid circulation region. Additionally, the one or more keyed guide rails may be specific to an individual rack unit or a type of rack units associated with electrical appliances. The one or more keyed guide rails may allow only the specific rack unit to be fitted into the corresponding immersion cooling system, and prevent other rack units from fitting in the immersion cooling system. The keyed components on the internal support structure and the rack-mounted server system 106 may comprise a visual indicator to conveniently identify matching keyed features.

[0019] Figure 2 shows another embodiment of an internal support structure 202 of an immersion cooling system 100, according to various aspects of the present invention. The internal support structure 202 may comprise all features of the first internal support structure 102 of Figure 1 and further comprise vertically-oriented guide rails 230. The guide rails 230 may be implemented in pairs adjacent to the long wall of the tank 101 and configured to receive universal mounting brackets 232 of the rack unit 104 when the rack unit 104 is installed in the tank 101. The universal mounting brackets 232 may be secured around the rack unit 104 and may be adjustably to the exterior dimensions of the rack unit 104. While the internal dimensions of the rack unit 104 (e.g., rack unit) may be standardized to fit the specific dimensions of electrical appliances 110, the exterior dimensions may not be specified by industry standards. The universal mounting bracket 232 may be configured to adjust to various exterior dimensions of the rack unit 104. Additionally, the exterior dimension of the universal mounting brackets 232 may be fixed and complementary to the interior dimensions of the guide rails 230. The guide rails 230 of the internal support structure 202 may be configured with internal dimensions that are slightly larger than the exterior dimensions of the universal mounting bracket 232, or sufficient to accommodate the exterior dimensions within a predetermined tolerance (e.g., + / - 5 mm). Each of the guide rails 230 may comprise a lip 234 at a lower end of the guide rail 230, where the lip 234 is configured to set a position of the rack unit 104 in an elevated position, above the bottom of the tank, or over a plenum that disperses and distributes the dielectric fluid uniformly through the appliances 110 mounted in the rack-mounted server system 106.

[0020] In one embodiment, the guide rails 230 may align supply and return connectors of distribution manifolds 240, mounted within the rack unit 104, with corresponding supply and return connections 242 positioned adjacent to the bottom 108 of the tank 101. As the rack 61607743887.5Docket No. 250168PCTunit 104 is lowered into the tank 101, the connectors of the distribution manifolds 240 may automatically engage with the supply and return connections 242 of the immersion cooling system. The distribution manifolds 240 may be coupled to a plurality of cold plates within the plurality of electrical appliances 110, as part of a second liquid cooling system. The dielectric liquid in the second cooling system may be separate and not fluidly coupled with the volume of dielectric liquid in the tank 101. The second cooling system may extract heat associated with specific components affixed with cold plates whereas the first cooling system, associated with the volume of dielectric liquid in the tank 101, may extract heat associated with the remaining non-cold plate components (e.g., everything other than the CPU and GPU affixed with cold plates). Accordingly, the dielectric liquid in the first cooling system and the second cooling system is separate and may comprise different fluid compositions.

[0021] In another embodiment, although the distribution manifolds 240 are originally designed for cold-plate liquid cooling systems, the supply and return distribution manifolds 240 may be retrofitted to direct and distribute dielectric fluid when fully immersed within a shared volume of dielectric fluid for the plurality of electrical appliances 110. Rather than supplying individual cooling lines to each electrical appliance, the distribution manifolds 240 may supply and remove dielectric liquid adjacent to the electrical appliances through the shared volume of dielectric fluid within the tank 101. The configuration creates an internal flow pattern within the tank 101 and through channels between the plurality of electrical appliances 110 that allows the distribution manifolds 240 to be retrofitted into the immersion cooling system based on a combination of a pressure differential between the supply and return manifolds, directional flow, and thermal convection.

[0022] The universal mounting brackets 232 may further comprise a plurality of anchor points 236 that receive anchors 238 that allow the rack-mounted server system 106 to be evenly and gradually lowered into place, such that the universal mounting brackets 232 align with the one or more guide rails 230 of the internal support structure. The anchors 238 may be configured based on the number of mounting brackets 232, the size of the rack unit 104, and equipment configured to lower the rack-mounted server system 106 in place.

[0023] Figures 3A-3C show a plurality of internal support structures 302 configured to receive various configurations of electrical appliances 110, according to various aspects of the present invention including the first internal support structure 102 and the second internal support structure 202. The internal support structure 302 may be configured to support two half-length server racks (e.g., 25-36 in), a single full-length server rack, a half-length server rack and individually mountable electrical appliances 110, or only individually mountable 71607743887.5Docket No. 250168PCTelectrical appliances 110. The internal support structures 302 may be configured with retractable mounting points 340 that adjustably mount to the top mounts 114. The retractable mounting points 340 allow the customer to customize the immersion system for individually mountable electrical appliances 110 and / or rack units 104.

[0024] Figure 3 A shows the retractable mounting points 340 in a retracted position, configured to support two half server rack (e.g., 25-36 in long) on or a single full length server rack in the immersion cooling system 100. In the retracted position, the retractable mounting points 340 do not impede the installation or removal of one or more rack-mounted server systems 106.

[0025] Figure 3B shows the retractable mounting points 340 in an extended position, configured to support only individually mountable electrical appliances 110. The extended position may be configured with internal dimensions based on an industry standard or trade association specification (e.g., Open Compute Project (OCP) Open Rack Specification) for rack-mounted servers.

[0026] Figure 3C shows a first retractable mounting points 342 in the retracted position and a second retractable mounting points 344 in the extended position, configured to support a half server rack (e.g., 25-36 in long) and individually mountable electrical appliances 110. The internal support structures 302 may be configured for a plurality of retractable mounting points to accommodate various different customer configurations.

[0027] Figures 4A-E show the steps for installing and / or removing a rack-mounted server system 106 in an immersion cooling system 100 comprising a first internal support structure 102, according to various aspects of the present invention.

[0028] Figure 4A shows a rack-mounted server system 106 comprising a plurality of electrical appliances 110, mounted to a rack unit 104. After an integration service has built the rack-mounted server system 106, they may affix a plurality of support members 450 (e.g., cables, chains, straps) to a plurality of connection points 452 on the rack unit 104 and raise the rack-mounted server system 106 off the ground and into the air with a machine 454 (e.g., crane, forklift).

[0029] Figure 4B shows the machine 454 positioning the rack-mounted server system 106 above the tank 101 of the immersion cooling system 100. The rack-mounted server system 106 is aligned with the internal support structure 102, where the rack-mounted server system 106 may be lowered to fit inside of the internal support structure 102.

[0030] Figure 4C shows the machine 454 lowering the rack-mounted server system 106 into the immersion cooling system 100, where the rack-mounted server system 106 is supported 81607743887.5Docket No. 250168PCTby the internal support structure 102. The rack unit 104 of the rack-mounted server system 106 may rest on a lip 234 of the internal support structure 102. Once the rack-mounted server system 106 is immersed in the dielectric fluid, the integration service may power on and configure the hardware and software components of the rack-mounted server system 106.

[0031] Figure 4D shows the removal of the rack-mounted server system 106 from the immersion cooling system. The support members 450 may be reaffixed to the rack unit 104 and raised above the tank 101 of the immersion cooling system 100. The rack-mounted server system 106 is positioned above the tank for a duration to allow the dielectric fluid to drain from the plurality of electrical appliances 110 into the tank 101.

[0032] Figure 4E shows the preparation of the rack-mounted server system 106 for shipping to the end customer. Once the majority of the dielectric fluid has drained from the rackmounted server system 106, a sealing enclosure 458 may be fitted around the rack-mounted server system 106. The sealing enclosure 458 may comprise a plurality of cut-outs that allow it to be placed around the rack-mounted server system 106 while it is still connected to the machine 454 by the support members 450. The sealing enclosure 458 prevents any remaining dielectric fluid from continuing to drain from the plurality of electrical appliances 110 once the rack-mounted server system 106 is sealed in a shipping crate 460. The machine 484 may position the rack-mounted server system 106 above the shipping crate 460. The machine 454 may lower the rack-mounted server system 106 into the shipping crate 460 and the support members 450 may be removed. The sealed enclosure 458 may be sealed at the plurality of cut-outs to further prevent any of the remaining dielectric fluid from leaking into the shipping crate 460. Alternatively, the shipping crate 460 may be lined with a sealing enclosure or liner, allowing the rack-mounted server system 106 to be placed directly into the crate and preventing any of the remaining dielectric fluid from leaking into the shipping crate 460.

[0033] Figures 5A-E show the steps for installing and / or removing a rack-mounted server system 106 in an immersion cooling system 100 comprising a second internal support structure 202, according to various aspects of the present invention. The steps of Figures 4A-E may be repeated with the universal mounting brackets 232 that align with the plurality of guide rails 230 of the internal support structure 202.

[0034] Examples of the method according to various aspects of the present disclosure are provided below in the following numbered clauses. An aspect of the method may include any one or more than one, and any combination of, the numbered clauses described below.

[0035] In one general aspect, therefore, the present invention is directed to immersion cooling systems and methods for installing pre-populated and configured rack units in the 91607743887.5Docket No. 250168PCTimmersion cooling systems. The immersion cooling system according to various embodiments includes a tank adapted to immerse in a dielectric fluid a plurality of electrical appliances, and an internal support structure configured to support a rack unit comprising the plurality of electrical appliances, where exterior dimensions of the rack unit are smaller and complementary to interior dimensions of the internal support structure. The internal support structure can receive and support the rack unit within the tank of the immersion cooling system. In this context, “smaller and complementary” can refer to the exterior dimensions of the rack unit being less than, and dimensionally matched to, the interior dimensions of the internal support structure within a predetermined tolerance such that the rack unit is receivable within the internal support structure with sufficient clearance to permit insertion and removal, while being guided and positionally constrained by the internal support structure to a predetermined orientation and position relative to one or more fluid distribution regions or infrastructure interfaces within the tank.

[0036] In various embodiments, the internal support structure is not merely configured to receive the rack unit, but is further configured to position the rack unit in a predetermined location and orientation within the tank. Such positioning may be achieved by one or more load-bearing members, alignment members, or guiding structures that constrain translational and / or rotational degrees of freedom of the rack unit during and after insertion. The predetermined location may correspond to alignment of the rack unit with one or more functional regions of the immersion cooling system, including fluid distribution regions, fluid return regions, power interfaces, or network interfaces. In this manner, the internal support structure provides controlled and repeatable positioning of the rack unit relative to the immersion cooling environment. In various embodiments, the internal support structure 102 further constrains the position of the rack-mounted server system 106 within the tank 101, such that the rack-mounted server system 106 is maintained in a predetermined position and orientation relative to the tank. This constraint may limit translational and / or rotational movement of the rack-mounted server system 106 once installed.

[0037] In various implementations of the immersion cooling system, the internal support structure comprises a bottom mount lip configured with internal dimensions to support the rack unit. Additionally, the bottom mount lip is configured to position the rack unit in an elevated position above the bottom of the tank and / or is configured to position the rack unit above a plenum.

[0038] In various implementations of the immersion cooling system, the internal support structure comprises guide rails configured with internal dimensions that are slightly larger 101607743887.5Docket No. 250168PCTand complementary to universal mounting brackets, or sufficient to accommodate the exterior dimensions within a predetermined tolerance (e.g., + / - 5 mm). The guide rails are adjacent to long walls of the tank, and the universal mounting brackets are configured to adjustably couple to the exterior of the rack unit. Additionally, the guide rails are configured to position the rack unit above a plenum and align a plurality of orifices of the plenum with appliance slots of the rack unit; the universal mounting brackets comprise a plurality of anchor points, where the plurality of anchor points are configured to removably couple anchors in various configurations, and / or the exterior dimensions of the universal mounting brackets are fixed and interior dimensions of the universal mounting brackets are adjustably configure to a predetermined range of exterior dimensions of the rack unit.

[0039] In various implementations of the immersion cooling system, the internal support structure comprises retractable mounting points along a top mount of the internal support structure. The retractable mounting points are configurable in a first position and a second position, where the first position is retracted to allow for an installation of the rack unit and the second position is extended to allow the plurality of electrical appliances to individually mount to the retractable mounting points. Additionally, the retractable mounting points are configurable to support a plurality of electrical appliance configurations, including a full rack unit, two half rack units, a half rack unit and a plurality of individual mounted electrical appliances, and only the plurality of individual mounted electrical appliances individually.

[0040] In various implementations, the immersion cooling system further comprises power and network management infrastructure corresponding to power components and network components of the rack unit, where the power and network management infrastructure is positioned along one or more walls of the tank.

[0041] In various implementations of the immersion cooling system the internal support structure comprises keyed guide rails configured with internal dimensions that are slightly larger and complementary to one or more keyed features of the rack unit, where the keyed guide rails allow only the rack unit with the one or more keyed features to be installed in the immersion cooling system.

[0042] In another general aspect, the present invention is directed to methods of installing rack units in an immersion cooling system. The method includes a first step of affixing a plurality of support members to a rack unit, where the rack unit is positioned along a horizontal axis, and where the rack unit is populated with a plurality of electrical appliances. The method continues by raising the rack unit off the ground by the plurality of support members and positioning the rack unit above an immersion cooling system adapted to111607743887.5Docket No. 250168PCTimmerse, in a dielectric fluid, the plurality of electrical appliances. Once the rack unit is positioned above, the method includes aligning the rack unit with an internal support structure of the immersion cooling system, where exterior dimensions of the rack unit are smaller and complementary to interior dimensions of the internal support structure, lowering the rack unit into the immersion cooling system, where the internal support structure receives and supports the rack unit within a tank of the immersion cooling system, and disconnecting the plurality of support members from the rack unit. In various embodiments, the rack unit may be oriented within the tank in any suitable orientation, including horizontal, vertical, or angled orientations. The particular orientation may be selected based on design considerations such as fluid flow characteristics, spatial constraints, or infrastructure layout. Accordingly, the internal support structure may be configured to receive and position the rack unit in any such orientation, and the examples described herein with respect to a horizontal orientation are not intended to be limiting.

[0043] In various implementations, the method further includes step of affixing one or more universal mounting brackets around the rack unit. The one or more universal mounting brackets comprise a plurality of anchors used to affix the plurality of support members to the rack unit, and the internal support structure comprises a plurality of guide rails configured to align a position of the rack unit within the tank based on the one or more universal mounting brackets. In various embodiments, the internal support structure may comprise one or more load-bearing and / or alignment features selected from a group including, but not limited to, rails, ledges, lips, saddles, brackets, pins, detents, slots, channels, or compliant members. Such features may be rigid or resilient and may be fixed, adjustable, or reconfigurable. The internal support structure may utilize any combination of these features to receive, guide, and / or constrain the rack unit within the tank. In some embodiments, the internal support structure may omit guide rails or universal mounting brackets and instead rely on alternative structures to position and support the rack unit in a predetermined location. In other embodiments, the internal support structure may be modular or configurable to accommodate rack units of different sizes, geometries, or configurations.

[0044] In various implementations, the method further includes steps of powering-on the plurality of electrical appliances, configuring a customer selected software application, and verifying compatibility among the plurality of electrical appliances and the customer selected software applications.

[0045] In various implementations, the method further includes steps of re-affixing the plurality of support members to the rack unit, where the rack unit is positioned within the 121607743887.5Docket No. 250168PCTinternal support structure of the tank, raising the rack unit by the plurality of support members above the tank of the immersion cooling system, and maintaining an elevated position above a top liquid level of the dielectric fluid within the tank, where residual fluid within the plurality of electrical appliances drains into the tank of the immersion cooling system.

[0046] In various implementations, the method further includes step of enveloping the rack unit in a sealing enclosure, where the sealing enclosure traps any remaining dielectric fluid within the sealing enclosure. A top portion of the sealing enclosure comprises a plurality of access points to envelop around the plurality of support members. The method can also comprise the step lowering the rack unit into a shipping container.

[0047] In another general aspect, therefore, the present invention is directed to immersion cooling systems and methods for installing pre-populated and configured rack units in the immersion cooling systems. The immersion cooling system according to various embodiments includes a tank adapted to immerse in a dielectric fluid a plurality of electrical appliances, an internal support structure, and a plurality of infrastructure connection points corresponding to power components and network components of the rack unit. The internal support structure is configured to support a rack unit comprising the plurality of electrical appliances, where exterior dimensions of the rack unit are smaller and complementary to interior dimensions of the internal support structure, and where the internal support structure receives and supports the rack unit within the tank of the immersion cooling system. And the plurality of infrastructure connection points positioned along one or more walls of the tank.

[0048] In certain embodiments, positioning the rack unit in a predetermined location within the internal support structure improves thermal performance by aligning heat-generating components of the electrical appliances with fluid flow paths within the dielectric fluid, thereby enhancing convective heat transfer and reducing localized thermal gradients. In certain embodiments, the internal support structure constrains positioning of the rack unit to reduce flow bypass regions and promote uniform distribution of dielectric fluid through interstitial spaces between electrical appliances.

[0049] The examples presented herein are intended to illustrate potential and specific implementations of the present invention. It can be appreciated that the examples are intended primarily for purposes of illustration of the invention for those skilled in the art. No particular aspect or aspects of the examples are necessarily intended to limit the scope of the present invention. Further, it is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear131607743887.5Docket No. 250168PCTunderstanding of the present invention, while eliminating, for purposes of clarity, other elements. While various embodiments have been described herein, it should be apparent that various modifications, alterations, and adaptations to those embodiments may occur to persons skilled in the art with attainment of at least some of the advantages. Persons skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flow diagrams are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. The disclosed embodiments are therefore intended to include all such modifications, alterations, and adaptations without departing from the scope of the embodiments as set forth herein.141607743887.5

Claims

Docket No. 250168PCTCLAIMSWhat is claimed is:

1. An immersion cooling system comprising:a tank adapted to immerse in a dielectric fluid a plurality of electrical appliances; and an internal support structure within the tank, wherein the internal support structure is configured to support a rack unit comprising the plurality of electrical appliances, wherein exterior dimensions of the rack unit are smaller and complementary to interior dimensions of the internal support structure, and wherein the internal support structure receives the rack unit within the tank of the immersion cooling system.

2. The immersion cooling system of claim 1, wherein the internal support structure comprises a bottom mount lip configured with internal dimensions to support the rack unit, wherein the rack unit is oriented along a horizontal axis during immersion.

3. The immersion cooling system of claim 2, wherein the bottom mount lip is configured to position the rack unit in an elevated position above the bottom of the tank.

4. The immersion cooling system of claim 2, wherein the bottom mount lip is configured to position the rack unit above a plenum.

5. The immersion cooling system of claim 1, wherein the internal support structure comprises guide rails configured with internal dimensions that are slightly larger and complementary to universal mounting brackets, wherein the guide rails are adjacent to long walls of the tank, and wherein the universal mounting brackets are configured to adjustably couple to the exterior of the rack unit.

6. The immersion cooling system of claim 5, wherein the guide rails are configured to position the rack unit above a plenum and align a plurality of orifices of the plenum with appliance slots of the rack unit.

7. The immersion cooling system of claim 5, wherein the universal mounting brackets comprise a plurality of anchor points, wherein the plurality of anchor points are configured to removably secure anchors in various configurations.151607743887.5Docket No. 250168PCT8. The immersion cooling system of claim 5, wherein exterior dimensions of the universal mounting brackets are fixed and interior dimensions of the universal mounting brackets are adjustably configured to a predetermined range of exterior dimensions of the rack unit.

9. The immersion cooling system of claim 1, wherein the internal support structure comprises retractable mounting points along a top mount of the internal support structure, wherein the retractable mounting points are configurable in a first position and a second position, wherein the first position is retracted to allow for an installation of the rack unit and the second position is extended to allow the plurality of electrical appliances to individually mount to the retractable mounting points.

10. The immersion cooling system of claim 9, wherein the retractable mounting points are configurable to support a plurality of electrical appliance configurations, including a full rack unit, two half rack units, a half rack unit and a plurality of individual mounted electrical appliances, and only the plurality of individual mounted electrical appliances individually.

11. The immersion cooling system of claim 1, further comprising power and network management infrastructure corresponding to power components and network components of the rack unit, wherein the power and network management infrastructure is positioned along one or more walls of the tank.

12. The immersion cooling system of claim 1, wherein the internal support structure comprises keyed guide rails configured with internal dimensions that are slightly larger and complementary to one or more keyed features of the rack unit, wherein the keyed guide rails allow only the rack unit with the one or more keyed features to be installed in the immersion cooling system.

13. The immersion cooling system of claim 1, wherein the tank comprises one or more motion dampers configured to couple the internal support structure to the tank, wherein the one or more motion dampers allows for a predetermined amount of movement between the internal support structure and tank.161607743887.5Docket No. 250168PCT14. The immersion cooling system of claim 1, wherein the rack unit comprises one or more distribution manifolds configured to fluidly couple with supply and return connections positioned adjacent to a bottom of the tank, and wherein the one or more distribution manifolds are configured to distribute and recover the dielectric fluid through a shared volume of the dielectric fluid surrounding the plurality of electrical appliances.

15. The immersion cooling system of claim 1, wherein the rack unit comprises a busbar configured to distribute DC power to the plurality of electrical appliances while the rack unit is immersed in the dielectric fluid.

16. The immersion cooling system of claim 15, wherein the internal support structure is configured to position the rack unit such that the busbar aligns with a corresponding power source positioned along one or more walls of the tank.

17. A method comprising:affixing a plurality of support members to a rack unit, wherein the rack unit is positioned along a horizontal axis, wherein the rack unit is populated with a plurality of electrical appliances;raising the rack unit off the ground by the plurality of support members;positioning the rack unit above an immersion cooling system adapted to immerse, in a dielectric fluid, the plurality of electrical appliances;aligning the rack unit with an internal support structure of the immersion cooling system, wherein exterior dimensions of the rack unit are smaller and complementary to interior dimensions of the internal support structure;lowering the rack unit into the immersion cooling system, wherein the internal support structure secures the rack unit in place within a tank of the immersion cooling system; anddisconnecting the plurality of support members from the rack unit.

18. The method of claim 17, further comprising:securing one or more universal mounting brackets around the rack unit, wherein the one or more universal mounting brackets comprise a plurality of anchors used to affix the plurality of support members to the rack unit, and wherein the internal support structure 171607743887.5Docket No. 250168PCTcomprises a plurality of guide rails configured to align a position of the rack unit within the tank based on the one or more universal mounting brackets.

19. The method of claim 17, further comprising:powering-on the plurality of electrical appliances;configuring a customer selected software applications; andverifying compatibility among the plurality of electrical appliances and the customer selected software applications.

20. The method of claim 19, further comprising:re-affixing the plurality of support members to the rack unit, wherein the rack unit is positioned within the internal support structure of the tank;raising the rack unit by the plurality of support members above the tank of the immersion cooling system; andmaintaining an elevated position above a top liquid level of the dielectric fluid within the tank, wherein residual fluid within the plurality of electrical appliances drains into the tank of the immersion cooling system.

21. The method of claim 19, further comprising:enveloping the rack unit in a sealing enclosure, wherein the sealing enclosure traps any remaining dielectric fluid within the sealing enclosure, and wherein a top portion of the sealing enclosure comprises a plurality of access points to envelop around the plurality of support members.

22. The method of claim 19, further comprising: lowering the rack unit into a shipping container.

23. An immersion cooling system comprising:a tank adapted to immerse in a dielectric fluid a plurality of electrical appliances;an internal support structure within the tank, wherein the internal support structure is configured to support a rack unit comprising the plurality of electrical appliances, wherein exterior dimensions of the rack unit are smaller and complementary to interior dimensions of the internal support structure, and wherein the internal support structure receives the rack unit within the tank of the immersion cooling system; and181607743887.5Docket No. 250168PCTa plurality of infrastructure connection points corresponding to power components and network components of the rack unit, wherein the plurality of infrastructure connection points positioned along one or more walls of the tank.

24. An internal support structure for use in an immersion cooling system, comprising: one or more load-bearing members configured to receive a rack unit supporting a plurality of electrical appliances;one or more alignment members configured to align the rack unit in a predetermined position relative to a dielectric fluid flow region when installed in a tank of the immersion cooling system; andone or more elevation members configured to support the rack unit above a bottom surface of the tank.191607743887.5

Images