Rack Cooling Door Heat Exchangers With Redundant Fluid Paths
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Solution Overview
Problem
Conventional cooling methods for high-performance electronics servers, such as blade and rack servers, are inadequate due to high thermal density and limited space, requiring supplemental cooling beyond what Computer Room Air Conditioning (CRAC) units can provide, and existing supplemental cooling systems face inefficiencies and wear and tear issues with hose connections.
Innovation Solution
A cooling door assembly with integrated heat exchangers that maintains a fluidic connection to an external cooling system without plumbing within the server rack, using flexible hoses and metal tubes to allow for refrigerants like R-134, and includes swivel joints for fluid paths and interchangeable mounting blocks to optimize fluid flow and reduce pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If supplemental cooling systems with hoses are used to cool high-density electronics servers, then cooling capacity is improved, but wear and tear on hose connections increases and system reliability deteriorates
Solution Approach 1:
The patent extracts the hose connection issue by providing a fixed mounting structure with integrated fluid ports that connect directly to the cooling system, eliminating the need for flexible hoses and their associated wear and tear problems while maintaining supplemental cooling capacity
Solution Approach 2:
The mounting structure is divided into separate modular components including the fixed mounting frame, fluid distribution manifold, and heat exchanger elements, allowing for easier maintenance and replacement without affecting the entire cooling system
2Device complexity
If conventional air cooling methods are used for high-density servers, then device simplicity is maintained, but cooling effectiveness becomes inadequate
Solution Approach 1:
The patent transitions from air cooling to liquid cooling by implementing a fluid distribution manifold that delivers coolant directly to heat exchangers mounted on server components, providing superior cooling effectiveness for high-density electronics while maintaining reasonable system complexity
Solution Approach 2:
The cooling system applies liquid cooling specifically to high-heat-density areas through strategically positioned heat exchangers and fluid ports, rather than uniformly cooling the entire server rack, optimizing cooling effectiveness where it is most needed
3Temperature
If CRAC units are used for cooling server racks, then basic cooling is provided, but supplemental cooling capacity is required for high thermal density
Solution Approach 1:
The patent implements preliminary cooling action by mounting heat exchangers directly on server components before heat is generated, and using a fixed mounting structure with pre-configured fluid ports that enable immediate liquid cooling deployment without requiring additional supplemental cooling equipment
Solution Approach 2:
The patent merges the mounting structure with the fluid distribution system, combining structural support functions with cooling delivery functions in a single integrated assembly that eliminates the need for separate CRAC and supplemental cooling systems
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
Enhances cooling capacity while minimizing the need for additional fans and reducing wear on components, providing efficient heat transfer and flexible installation options without modifying the server cabinet.
Implementation Method 1
Device and methodology for the removal of heat from an equipment rack by means of heat exchangers mounted to a door
Data Source
AI summary
A cooling door assembly includes a frame and a cooling door coupled to the frame. The cooling door includes multiple heat exchangers. The frame is configured to mount to the back of a server rack or other electronics enclosure in such a manner that the cooling door opens to allow access to the electronics servers within the server rack while maintaining a fluidic connection to an external cooling system. The frame is coupled to the external cooling system and the cooling door includes one or more swivel joints, each configured to provide one or more fluid paths between the cooling door and the frame. The cooling door assembly includes separate and independent fluid paths, where fluid is separately provided to each independent fluid path. Different groups of heat exchangers are coupled to each independent fluid path. In the event of failure of one of the independent fluid paths, the other independent fluid path(s) remain operational.