Rack Cooling Plenum Layout for Dense Enclosure Heat Dissipation
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Solution Overview
Problem
Existing cooling systems for rack-mounted heat dissipating components in enclosed spaces face challenges in efficiently managing heat dissipation due to the need for multiple fan assemblies and limited space for HVAC air supply and return separation, which restricts the number of racks that can be deployed.
Innovation Solution
A component cooling system that includes an air plenum at the rear of each rack to create an air channel, a single air mover at the bottom of each rack to pressurize the plenum, and an air cooling system that directs cool air between rows of racks, using a cool air duct to prevent mixing of warm and cool air, allowing for efficient heat dissipation without the need for multiple fans within each component.
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 combines multiple individual fan assemblies into a single shared cooling infrastructure. A common plenum chamber collects exhaust heat from multiple rack-mounted components, and a single fan assembly located in the HVAC return air path conveys this consolidated heat away. This merging reduces the total number of fan assemblies from multiple per component to just one shared assembly, thereby reducing device complexity and cost while maintaining heat dissipation effectiveness.
Solution Approach 2:
The single fan assembly serves multiple functions: it draws cooled air through the plenum chamber, conveys heat from multiple different rack-mounted components simultaneously, and integrates with the existing HVAC return air path. This multi-functionality allows one fan assembly to replace what would traditionally require multiple separate fan assemblies, reducing overall system complexity.
2Temperature
If standard HVAC cooling is used to maintain ambient temperature in the enclosure, then overall temperature control is improved, but the separation between air supply and return ports limits the number of racks that can be deployed
Solution Approach 1:
The plenum chamber acts as an intermediary element between the rack-mounted components and the HVAC system. It provides a dedicated space for heat collection and air flow management, allowing the HVAC return air path to be extended or reconfigured without requiring immediate physical separation between supply and return ports. This intermediary structure enables more flexible spatial arrangement of HVAC components within the enclosure.
Solution Approach 2:
The invention utilizes the vertical dimension by positioning the plenum chamber above the rack-mounted components and extending the HVAC return air path vertically. This dimensional approach allows the system to accommodate more racks in horizontal space while maintaining proper HVAC air flow separation through vertical routing, effectively increasing rack deployment density without compromising temperature control.
3Device complexity
If a single air mover is used per rack to pressurize the air plenum, then device complexity and cost are reduced, but adequate heat dissipation must be maintained
Solution Approach 1:
The invention merges the cooling function of multiple individual air movers into a single shared air mover. The plenum chamber consolidates heat from multiple rack-mounted components, and one air mover in the HVAC return path handles the combined thermal load. This consolidation reduces device complexity while maintaining adequate heat dissipation through centralized thermal management.
Solution Approach 2:
The system uses pneumatic principles by creating pressurized air flow through the plenum chamber. The single air mover generates sufficient pressure to drive cooled air through the plenum and across multiple heat-generating components simultaneously. This pneumatic approach allows one air mover to perform the work of multiple smaller ones by utilizing pressure differential and air flow dynamics.
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 solution enables effective heat dissipation by using a single air mover per rack, reducing costs and increasing efficiency, while allowing for a higher density of rack deployment in enclosed spaces by optimizing air flow and temperature management.
Implementation Method 1
Because cool air is denser than warm air, cool air tends to flow (through the operation of convection) to the bottom of the volume between rows of racks
Implementation Method 2
cool the warm air to produce cool air
Implementation Method 3
force the air into the plenum, thereby pressurizing the air channel along the rear portion of the components
Data Source
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.