Rack Cooling Plenum Layout for Dense Enclosure Airflow
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Solution Overview
Problem
Existing cooling systems for rack-mounted heat dissipating components often require multiple fan assemblies and significant separation between HVAC air supply and return ports, which can be impractical in narrow enclosed systems.
Innovation Solution
A component cooling system that includes an air plenum at the rear of each rack to create an air channel, an air mover at the bottom of each rack to pressurize the plenum, and an air cooling system that receives warm air from between rows of racks, cools it, and recirculates the cool air to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple fan assemblies are used within each rack-mounted component to convey heat away, then heat dissipation effectiveness is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple individual fan assemblies into a single centralized air mover located in the aisle between rack rows. This air mover serves multiple racks simultaneously, reducing the total number of fan assemblies while maintaining effective heat dissipation across all components.
Solution Approach 2:
The centralized air mover performs multiple functions: it pressurizes the plenum, drives air through components, and can be adjusted to serve different racks. This multi-functional design eliminates the need for dedicated fans in each component, simplifying the overall system.
2Temperature
If significant separation between HVAC air supply and return ports is implemented, then cooling effectiveness is improved, but adaptability to narrow enclosed systems deteriorates
Solution Approach 1:
The cooling system is segmented into localized plenums at each rack that can be independently pressurized and managed. This allows each rack to function as an independent cooling zone, enabling effective cooling even when racks are densely packed with minimal aisle space.
Solution Approach 2:
The plenum acts as an intermediary between the centralized air mover and the components. It distributes pressurized cooling air to multiple components within the rack, enabling effective heat dissipation without requiring large physical separations between air supply and return points.
3Temperature
If the number of installed racks is limited to achieve required separation in available space, then HVAC cooling effectiveness is improved, but productivity and space utilization deteriorate
Solution Approach 1:
The air mover is extracted from individual components and placed in the aisle, allowing racks to be densely packed while maintaining cooling effectiveness. This extraction enables higher rack density without compromising temperature control.
Solution Approach 2:
The system transitions from horizontal air flow requirements to vertical air flow through plenums. By utilizing the vertical dimension within each rack, the system achieves effective cooling without requiring increased horizontal separation between racks, thereby maximizing space utilization.
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 system effectively reduces the need for multiple fan assemblies within components and allows for efficient cooling in confined spaces by utilizing a single air mover per rack and optimizing air circulation through the use of an air plenum and cooling system.
Implementation Method 1
an air cooling system configured to receive warm air from within the enclosure through a warm air port in an enclosure ceiling, cool the warm air to produce cooled air
Implementation Method 2
an air mover disposed at a bottom of the rack to pull air from outside of the rack and force the air into the plenum to pressurize the air channel
Implementation Method 3
The stacked arrangement of heat dissipating components may be configured to direct a flow of air from the pressurized air plenum into or around the heat dissipating components to outside of the rack in front of the components
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A method of cooling a rack of heat dissipating components comprises cooling air, and porting the cooled air into a volume in front of the rack from above the volume. The method further comprises moving the cooled air from the volume in front of the rack to a plenum at a rear portion of the rack to pressurize the plenum. The cooled air is moved with an air mover disposed at a bottom portion of the rack, The method also comprises flowing air from the pressurized plenum past or through heat dissipating components in the rack to the volume in front of the rack, by force of pressure in the plenum through air-directing ports in the plenum. The air may be flowed through the heat dissipating components, around the heat dissipating components, or both. The method further comprises drawing warm air from an upper portion of the volume in front of the racks to cool it again.