Integrated Rack Architecture for Two-Phase Coolant Distribution
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Solution Overview
Problem
Existing data center cooling systems, particularly CRAC units, struggle to effectively manage thermal environments for high-power density electronic racks, leading to inefficiencies and increased costs, and immersion cooling solutions require complex infrastructure modifications and maintenance disruptions.
Innovation Solution
An integrated rack architecture that distributes two-phase coolant directly to servers, incorporating a condensing region with coils and a coolant container, and a distribution region with adjustable manifolds for efficient heat transfer and vapor condensation, allowing for facility-level and rack-level co-design to enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CRAC units are used for cooling high-power density racks, then thermal environment can be maintained for conventional racks, but cooling effectiveness deteriorates for high-power density racks due to excessive heat generation rate
Solution Approach 1:
The patent transitions from air cooling (CRAC units) to liquid cooling by implementing a two-phase coolant system with liquid supply lines and vapor return lines that directly contact electronics, enabling effective heat removal from high-power density racks where air cooling becomes insufficient
Solution Approach 2:
The system utilizes two-phase coolant (liquid and vapor phases) where the coolant absorbs heat from electronics through phase change, with condensing coils converting vapor back to liquid, providing efficient thermal management for high-density configurations
2Reliability
If immersion cooling is implemented, then cooling efficiency for high-density electronics is improved, but device complexity increases due to complex infrastructure modifications and maintenance requirements
Solution Approach 1:
The immersion cooling system is divided into modular rack-level units with integrated condensing coils and coolant distribution manifolds, allowing independent deployment and maintenance of individual racks without shutting down entire data centers or modifying complex centralized infrastructure
Solution Approach 2:
The two-phase coolant system automatically circulates through the electronics and condensing coils without requiring external pumps or complex control systems, reducing operational complexity and eliminating pump failure risks associated with single-phase immersion cooling
3Loss of energy
If conventional two phase immersion cooling systems are used, then heat removal capacity is improved, but maintenance operations cause service interruption due to condenser removal requirements
Solution Approach 1:
The condensing coils are nested within the same rack enclosure as the electronics, with coolant distribution manifolds integrated into the rack structure, allowing maintenance of individual components without removing condensers or shutting down other servers in the same rack
4Loss of energy
If cooling fluid is moved closer to IT equipment, then heat removal efficiency is improved, but device complexity increases due to additional cooling distribution infrastructure
Solution Approach 1:
The cooling infrastructure is merged with the rack structure itself, where coolant distribution manifolds, supply lines, and vapor return lines are integrated into the rack enclosure, eliminating the need for separate cooling infrastructure and reducing overall system complexity
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 improves the design and deployment efficiency of high-power density compute clusters by directly addressing thermal management challenges, reducing airflow requirements, and minimizing service interruptions during maintenance.
Implementation Method 1
distributing two phase coolant to a plurality of servers
Implementation Method 2
Heat generated by the IT equipment is captured by the cooling air and is extracted by the cooling unit
Implementation Method 3
a condensing region that includes a condensing container housing condensing coils
Data Source
AI summary
An electronic rack includes condensing, coolant distribution, and server regions. The condensing region includes a condensing container housing condensing coils and a coolant container to contain two phase coolant. The coolant distribution region includes a set of rack manifolds having at least a rack liquid supply line to receive coolant from the coolant distribution region, and a vapor line to return vapor to the coolant distribution region, a liquid return line. The server region is coupled to the condensing region and the coolant distribution region, the server region includes a number of server slots to receive a number of servers, where each of the servers is at least partially submerged within two phase liquid coolant, where, when the servers operate, the servers generate heat that is extracted by the two phase liquid coolant thereby causing at least some of the two phase liquid coolant to turn into a vapor.