Liquid Manifold Mounting Interface for Precise Rack Port Alignment
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Solution Overview
Problem
Conventional liquid cooling systems face challenges in ensuring precise alignment and secure connection of fluid couplings between manifolds and electronics racks due to manufacturing variances, leading to potential leaks and poor cooling performance.
Innovation Solution
A server rack assembly with a mounting and alignment interface that includes a first planar portion with alignment holes and a rack support, which is coupled to the manifold, ensuring alignment and secure attachment of electronics trays to fluid ports, distributing reaction forces across multiple locations to reduce manifold deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional liquid cooling systems are used without a mounting and alignment interface, then the system structure is simpler, but the alignment precision of fluid ports deteriorates leading to potential leaks
Solution Approach 1:
The mounting and alignment interface is designed with pre-configured alignment holes and positioning features that guide the electronics rack into precise alignment with the manifold before fluid coupling engagement. This preliminary alignment action ensures fluid ports are correctly positioned before pressure is applied, preventing leaks while maintaining a relatively simple overall structure.
Solution Approach 2:
The mounting and alignment interface acts as an intermediary component between the manifold and the electronics rack. It provides a dedicated structure with alignment holes and positioning features that mediate the connection, ensuring precise alignment of fluid ports without requiring complex integrated solutions in either the manifold or rack design.
2Reliability
If electronics trays are secured without a mounting interface, then the installation process is faster, but the connection reliability deteriorates due to misalignment under fluid pressure
Solution Approach 1:
The mounting and alignment interface pre-positions alignment holes and positioning features that guide the electronics rack into correct alignment before fluid coupling engagement. This preliminary action ensures reliable connection under fluid pressure while maintaining a straightforward installation process requiring only engagement of the rack with the interface features.
Solution Approach 2:
The alignment holes and positioning features in the mounting interface enable the electronics rack to self-align and self-position during installation. The rack automatically engages with the alignment features, ensuring correct positioning without requiring complex adjustment procedures or specialized installation tools.
3Manufacturing precision
If manufacturing tolerances are not controlled, then production costs are lower, but the alignment precision of fluid couplings deteriorates leading to leaks
Solution Approach 1:
The mounting and alignment interface incorporates pre-configured alignment holes and positioning features that establish precise geometric relationships before final assembly. This preliminary configuration ensures accurate alignment of fluid couplings even when standard manufacturing tolerances are used, eliminating the need for tight tolerance controls in the manufacturing process.
Solution Approach 2:
The mounting interface serves as an intermediary that absorbs and compensates for manufacturing tolerances. By providing dedicated alignment holes and positioning features in this intermediate component, the system achieves precise fluid coupling alignment without requiring tight tolerances in the manifold or electronics rack manufacturing.
4Stability of the object's composition
If fluid forces are concentrated at single connection points, then the manifold structure is simpler, but the manifold deflection increases affecting alignment
Solution Approach 1:
The mounting and alignment interface provides multiple distributed connection points and support locations along the manifold. By segmenting the load distribution across multiple attachment points rather than concentrating forces at single points, the interface reduces manifold deflection and maintains alignment stability without requiring significant structural changes to the manifold itself.
Data Source
AI summary
A server rack assembly is provided for an electronics tray and a manifold for delivery of cooling flow to the electronics tray. Mounting and alignment features on the server rack assembly, such as alignment holes and planar support surfaces, can help to provide predictable alignment between fluid ports on the manifold and fluid ports on the electronics tray. The server rack assembly can include a mounting and alignment interface coupled to the manifold and a rack support that can be coupled to the mounting and alignment interface. An equipment stop can be coupled to the rack support and can extend perpendicular to a side portion of the rack support. The equipment stop can be configured to prevent the electronics tray from being installed beyond a predetermined distance.