Air Handling Unit Ceiling Mounting for Modular Data Center Cooling

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Solution Overview

Problem

Modular data centers (MDCs) face challenges in air handling due to the need for efficient cooling while maintaining a compact form for road transportation, as traditional air handling unit (AHU) configurations either exceed width limits or compromise the optimized layout of IT racks between hot and cold aisles.

Innovation Solution

The implementation of an air handling system with vertically spaced return and supply air inlets and outlets, coupled with a redirection structure that laterally directs air between AHUs and aisles, allowing for flexible placement of AHUs at either end of the MDC and enabling efficient cooling airflow management across multiple zones.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If wall-mounted AHUs are installed along the exterior wall adjacent to the cold aisle, then cooling functionality is provided, but the shipping MEDC exceeds lateral road width limits

Engineering Contradiction:

Improvecooling functionalityVSAvoidwidth

Core Design Contradiction:

TemperatureVSLength of moving object

Solution Approach 1:

The air handling units are mounted on the interior ceiling rather than the exterior wall, transitioning from a wall-mounted configuration to a ceiling-mounted configuration. This dimensional change allows the AHUs to be positioned over the cold aisle without increasing the lateral width of the container, thereby maintaining road transport compliance while providing the necessary cooling functionality.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If the MEDC layout is rearranged to accommodate side-mounted AHUs, then wall mounting costs are reduced, but the optimized straight longitudinal line of IT racks between hot and cold aisles is compromised

Engineering Contradiction:

Improveinstallation costVSAvoidIT rack layout

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The ceiling-mounted AHU configuration serves multiple functions: it provides cooling to both hot and cold aisles, maintains the optimized straight longitudinal IT rack layout, and allows for flexible positioning along the container length. This universal mounting approach eliminates the need to choose between cost-effective wall mounting and layout optimization, as the ceiling mounting achieves both goals simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Length of moving object

If wall mounting of AHUs is performed after shipping the MEDC, then road width limits are maintained, but overall deployment costs increase

Engineering Contradiction:

ImprovewidthVSAvoiddeployment cost

Core Design Contradiction:

Length of moving objectVSEase of manufacture

Solution Approach 1:

The AHUs are pre-installed on the interior ceiling during the manufacturing phase, before shipping. This preliminary installation allows the units to be securely mounted in the optimal position while the container is being assembled, avoiding the need for expensive post-shipment installation. The ceiling mounting structure is integrated into the manufacturing process, making the additional cost negligible compared to post-deployment installation.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables economical assembly and transportation of MDCs by maintaining a compact form while providing effective cooling to heat-generating IT components, optimizing the layout of IT racks and aisles, and allowing for adjustable cooling based on environmental conditions.

Implementation Method 1

The return air plenum is in fluid communication with and vertically aligned to the return air inlet of the at least one AHU. The return air plenum directs return air from a return air opening of the first air redirection structure to the return air inlet of the at least one AHU.

Methodology Applied

Scientific EffectFluid communication:

Implementation Method 2

The supply air plenum is in fluid communication with and vertically aligned to the supply air outlet of the at least one AHU. The supply air plenum directs supply air from the supply air outlet of the at least one AHU to a supply air opening of the first air redirection structure.

Methodology Applied

Scientific EffectFluid communication:

Data Source

PatentUS11006551B2Method for re-direction of airflow from air handler system(s) integrated into a modular data center

Publication Date: 2021.05.11 DELL PROD LP

AI summary

A modular data center (MDC) includes an air handling system having air handling unit(s) (AHU(s)) with return air inlet and supply air outlet that are vertically spaced. An air redirection structure includes a return air plenum that is in fluid communication with and vertically aligned to the return air inlet of the AHU(s). The return air plenum directs return air from a return air opening of the first air redirection structure to the AHU(s). The return air opening is positioned adjacent to a hot aisle of a volumetric container of the MDC. A supply air plenum is in fluid communication with and vertically aligned to the supply air outlet of the AHU(s). The supply air plenum directs supply air from the AHU(s) to a supply air opening of the first air redirection structure. The supply air opening is positioned to provide supply air to the cold aisle of the container.