Modular Cooling Door for Server Rack Heat Rejection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current server room cooling solutions, such as CRAC units, are inefficient and costly, especially in large server rooms, and lack robustness and customization options to handle varying server configurations and heat loads without risking damage to electronic components.
Innovation Solution
A modular cooling system with a hinged cooling door and heat exchanger mounting frame that allows for quick and tool-free placement of heat exchanger modules directly above servers, using micro-channel heat exchangers with refrigerant coolant, which minimizes energy usage and allows for easy customization and maintenance, and can operate without damaging servers in case of coolant leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If CRAC units are used to cool the entire server room, then the servers are kept at safe operating temperature, but energy consumption and operational costs increase exponentially
Solution Approach 1:
The cooling system is segmented into individual rack-level units rather than a centralized room-level system. Each cooling door assembly serves a specific server rack, allowing cooling capacity to be distributed and matched to actual heat loads at each location, thereby reducing overall energy consumption.
Solution Approach 2:
Cooling is applied locally at the rack level where heat is generated, rather than uniformly cooling the entire server room. The cooling door assemblies are positioned to cool only the air immediately surrounding the servers, creating localized cooling zones that reduce total energy requirements.
2Loss of energy
If cooling units are placed in close proximity to individual servers, then cooling efficiency improves, but the system complexity and customization requirements increase
Solution Approach 1:
The cooling door assembly is designed as a universal unit that can be applied to various server rack configurations. The standardized design with adjustable components allows a single basic unit to serve multiple different cooling needs, reducing overall system complexity while maintaining high cooling efficiency.
Solution Approach 2:
The cooling system incorporates adjustable and adaptable components that can be configured dynamically to match different server rack layouts and heat loads. This flexibility allows the system to optimize cooling efficiency for each specific application without requiring completely different designs.
3Temperature
If coolant lines are installed for heat exchangers, then effective cooling is achieved, but the risk of coolant leaks and damage to electronic components increases
Solution Approach 1:
The system uses refrigerant-based heat exchangers where the coolant is contained in a closed loop system. While refrigerant leaks are possible, the use of environmentally friendly refrigerants and the ability to quickly service or replace individual heat exchanger units minimizes the harmful impact compared to alternatives.
Solution Approach 2:
The heat exchanger acts as an intermediary between the coolant and the server air. The refrigerant cools a heat exchange surface that then cools the server air indirectly, preventing direct contact between coolant and electronic components while still achieving effective cooling.
4Ease of manufacture
If fixed cooling configurations are used, then installation is simplified, but adaptability to varying server rack configurations is reduced
Solution Approach 1:
The cooling door assembly is divided into modular segments that can be independently configured. Heat exchanger modules and fans can be adjusted or repositioned within the standardized housing to accommodate different server rack configurations, maintaining installation simplicity while providing adaptability.
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
The system provides efficient and customizable cooling, reducing energy consumption and operational costs by targeting heat directly at server locations, while ensuring safety and ease of maintenance, and accommodating varying server configurations and rack heights.
Implementation Method 1
A heat exchanger is provided for cooling the heated air
Implementation Method 2
using micro-channel heat exchangers with refrigerant coolant
Data Source
AI summary
The present invention is directed to apparatus and methods for cooling computer servers and/or electrical equipment in a rack device for data centers or telecommunication centers.