Sealed Cable Assembly for Immersion Cooling Fluid Leakage
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Solution Overview
Problem
Data centers face fluid leakage issues through cables connected to immersion cooling tanks, leading to wastage of expensive cooling fluids, necessitating the development of more effective sealing solutions for data and power cables.
Innovation Solution
The implementation of sealed cable assemblies with a jacket enclosing insulated wires, featuring an air gap between the jacket and wires, and the application of a sealant to fill this gap, particularly at connector locations or in-between sections, to prevent fluid leakage. This involves stripping insulation, applying a liquid epoxy or sealant, and mechanically coupling connectors before the sealant cures, optionally wrapping with weatherproof tape or film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are used to connect electronic components in immersion cooling tanks, then power and data transmission is enabled, but cooling fluid leaks through the cables causing expensive fluid loss
Solution Approach 1:
The cable structure is segmented into distinct zones: an inner region containing insulated wires and an outer jacket, with an air gap separating them. Sealant is applied at specific locations within this segmented structure to create multiple sealing barriers, preventing fluid leakage while maintaining cable functionality.
Solution Approach 2:
A sealant material is introduced as an intermediary substance between the insulated wires and the outer jacket. This sealant fills the air gap and creates a fluid-tight barrier, mediating between the internal cable components and the external cooling fluid environment to prevent leakage.
2Reliability
If sealant is applied to fill air gaps in cables, then fluid leakage is prevented, but cable flexibility may be reduced
Solution Approach 1:
The sealant is applied locally at specific positions along the cable where fluid leakage is most likely to occur, rather than throughout the entire cable length. This localized application provides effective sealing while preserving cable flexibility in other regions that require movement and bending.
Solution Approach 2:
Rather than completely filling the entire air gap along the full cable length, the sealant is applied partially at strategic locations to provide sufficient sealing effectiveness. This partial action prevents leakage while avoiding excessive sealant that would compromise cable flexibility.
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 solution significantly reduces fluid loss by sealing air gaps within the cables, maintaining their flexibility and heat resistance, and can be applied at multiple locations along the cables for enhanced protection.
Implementation Method 1
A sealant surrounds the insulated wires in the air gap between the jacket and the insulated wires in a location along the jacket, and the sealant fills the air gap at the location
Data Source
AI summary
A sealed cable assembly includes a jacket enclosing a plurality of insulated wires. Each insulated wire includes a bare wire covered by surrounding insulation, and a cable plug or connector is electrically connected with the bare wires. A sealant surrounds the insulated wires in an air gap between the jacket and the insulated wires in a location at or near the cable plug or connector, and the sealant fills the air gap at the location to prevent or reduce fluid loss through the cable in an immersion cooling system. The cable assembly can also be sealed at an in-between section away from the cable plug or connector. The cable assembly is wrapped with a weatherproof film or tape at the location of the sealing to further prevent or reduce fluid loss through the cable.