Modular Indirect Evaporative Cooler Heat Exchanger
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Solution Overview
Problem
Existing indirect evaporative cooler (IEC) systems for data centers are large, bulky, expensive, difficult to install and maintain, and require the entire assembly to be discarded if any part fails a leak test.
Innovation Solution
A modular cooling unit is constructed using overmolded headers and tubes with extended surfaces for watertight connections, allowing for individual module replacement and assembly in various configurations, reducing manufacturing and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-piece polymer cooling core is used, then the structure is simple and manufacturing is straightforward, but the system becomes large and bulky, difficult to install and service
Solution Approach 1:
The cooling core is divided into multiple modular segments that can be independently manufactured, transported, and assembled. Each module contains a portion of the tubes and headers, allowing the system to be constructed from smaller, more manageable units rather than a single large one-piece structure.
2Ease of manufacture
If a one-piece polymer cooling core is used, then the structure is simple, but the system becomes expensive to manufacture, operate, and maintain
Solution Approach 1:
By segmenting the cooling core into modular units, each module can be manufactured independently using optimized processes, reducing overall manufacturing complexity and cost. The modular approach allows for parallel production and reduces material waste.
Solution Approach 2:
The modular design enables individual modules to be replaced rather than the entire cooling core, reducing maintenance costs and operational downtime. Failed modules can be discarded and replaced with new or refurbished units.
3Ease of manufacture
If a one-piece polymer cooling core is used, then the structure is simple, but if any part fails air or water leak tests, the entire assembly has to be removed and discarded
Solution Approach 1:
The cooling core is divided into multiple modular segments with independent leak paths. If one module fails a leak test, only that specific module needs to be replaced rather than the entire cooling core, significantly reducing waste and maintenance costs.
Solution Approach 2:
The modular design provides a built-in safety mechanism where leak testing can be performed on individual modules before final assembly. This prevents the need to discard the entire system if a leak is detected in one module.
4Quantity of substance
If large assemblies are used, then the cooling capacity is sufficient, but the system becomes difficult to install and service
Solution Approach 1:
The cooling core is divided into multiple modular segments that can be independently manufactured, transported, and assembled. Each module contains a portion of the tubes and headers, allowing the system to be constructed from smaller, more manageable units rather than a single large one-piece structure.
Solution Approach 2:
The modular design allows the cooling system to be scaled by adding or removing modules in different configurations, enabling flexible adaptation to various space constraints and cooling requirements without being limited to fixed large assemblies.
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 modular approach enables easier installation, reduced costs, and the ability to replace malfunctioning modules without discarding the entire cooling core, improving efficiency and ease of maintenance.
Implementation Method 1
Overmolding may allow the extended surfaces of the plurality of parallel first slots to form over the first ends of the plurality of tubes to create a watertight connection between the first header and the first ends of the plurality of tubes
Implementation Method 2
applying an adhesive in at least one of the top, bottom, first side, and second side grooves
Implementation Method 3
The at least one spline may be dimensioned to be received and retained by and extend across at least a portion of the top, bottom, first side, and second side grooves
Implementation Method 4
The polymer core may include a plurality of tubes that function to exchange heat associated with air coming in from the data center
Data Source
Figure 1A~1B
Figure 1C
Figure 1D~1F
AI summary
A method for constructing a module of a modular cooling unit includes acquiring a plurality of tubes, each tube having a first end and a second end, and overmolding a first header onto the first ends of the plurality of tubes to form a watertight connection between the first header and the first ends of the plurality of tubes, the first header having a plurality of parallel first slots, each slot of the parallel first slots having an extended surface configured to receive and retain the first end of the tube.