Hybrid-Cooled Server Rack with Liquid and Air Cooling Segmentation
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Solution Overview
Problem
Data centres face challenges in optimizing power, cooling, and space utilization due to increased demand for data storage, requiring more efficient cooling and power management systems.
Innovation Solution
A hybrid cooling system is implemented in servers, combining liquid cooling for high heat flux components and air cooling for low heat flux components, with heat exchangers and fans to manage temperature and airflow, allowing operation at high ambient temperatures and eliminating the need for chillers and traditional cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional air cooling systems are used for all components, then the cooling system is simple to implement, but the power consumption and cooling efficiency deteriorate due to high airflow requirements
Solution Approach 1:
The cooling system is segmented into two distinct subsystems: liquid cooling for active components and air cooling for passive components. This segmentation allows each subsystem to be optimized for its specific cooling needs, with liquid cooling providing high efficiency for heat-intensive components without requiring high airflow rates, thereby reducing overall power consumption while maintaining implementation simplicity through modular design
Solution Approach 2:
Different cooling methods are applied to different components based on their local heat generation characteristics. Active components with high heat flux receive liquid cooling with superior heat transfer properties, while passive components with low heat flux use standard air cooling. This local differentiation optimizes power efficiency by applying intensive cooling only where necessary rather than uniformly across all components
2Reliability
If liquid cooling is applied to all components, then cooling efficiency improves, but device complexity and cost increase
Solution Approach 1:
The system segments cooling application to only active components that generate significant heat, rather than applying liquid cooling to all components. This selective approach maintains high cooling efficiency where needed while avoiding the complexity and cost of liquid cooling infrastructure for passive components that don't require it
Solution Approach 2:
Liquid cooling is applied locally only to active components with high heat flux requirements, while passive components continue to use simpler air cooling. This localized application maintains optimal cooling efficiency for heat-generating components without unnecessarily increasing overall system complexity
3Reliability
If high airflow is used for cooling, then cooling capacity increases, but space requirements and structural complexity increase due to raised floors and overhead plenums
Solution Approach 1:
The invention extracts and eliminates the requirement for raised floors and overhead plenums by using liquid cooling for active components. Since liquid cooling does not require high airflow rates, the complex ducting networks and plenum structures traditionally needed for data center cooling are removed, significantly reducing space requirements while maintaining adequate cooling capacity
Solution Approach 2:
The system transitions from pneumatic cooling (high airflow) to hydraulic cooling (liquid circulation) for active components. This substitution eliminates the need for large-volume airflow infrastructure such as raised floors and overhead plenums, as liquid cooling achieves superior heat removal efficiency through direct contact and circulation rather than relying on high-volume air movement
4Reliability
If traditional cooling systems with chillers are used, then cooling performance is reliable, but power utilization efficiency deteriorates
Solution Approach 1:
The invention extracts and eliminates the chiller component from the cooling system by using liquid cooling with passive or active heat exchangers. This removal of the chiller eliminates the associated high power consumption while maintaining reliable cooling performance through direct liquid-to-component heat transfer and efficient heat dissipation at the source
Solution Approach 2:
The liquid cooling system enables servers to self-regulate their thermal management through integrated cooling channels and heat exchangers. Active components are cooled directly by liquid circulation without requiring centralized chiller systems, allowing each server to manage its own thermal load efficiently and reducing overall power utilization
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 approach achieves at least 50% reduction in airflow, eliminates the need for raised floors and overhead plenums, and results in ultra-low power utilization efficiency and increased server density, enabling energy savings and efficient space use in data centres.
Implementation Method 1
A plurality of liquid cooling devices is attached to respective ones of the active components
Implementation Method 2
One or more heat exchangers are arranged to remove heat from a cooling liquid and a gaseous flow passing through the servers
Implementation Method 3
A plurality of fans is arranged to draw ambient air through the servers and the first heat exchanger
Data Source
AI summary
A server (10), a server rack (50) and a data centre (100, 150) are provided. The server (10) includes a housing (12) defining a gaseous flow passage. A plurality of active components (14) and a plurality of passive components (16) are provided in the housing (12). A plurality of liquid cooling devices (18) is attached to respective ones of the active components (14).