Self-Expanding Gap Filler for Data Center Air Leakage

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Solution Overview

Problem

In data centers with hot and cold aisles, gaps between server rack cabinets, the floor, and containment systems lead to undesirable air mixing, increasing cooling air temperatures and reducing cooling efficiency.

Innovation Solution

A self-expanding gap filler with a compressible material encapsulated in an outer layer is placed in gaps between adjacent elements in a data center. The outer layer is sealed in a compressed state, and upon deployment, the seal is partially released to allow air to expand the compressible material, filling the gap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If server rack cabinets are arranged in hot and cold aisles with containment structures, then cooling efficiency is improved, but gaps between adjacent cabinets allow air leakage that reduces this efficiency

Engineering Contradiction:

Improvecooling efficiencyVSAvoidgap sealing

Core Design Contradiction:

Loss of energyVSEase of manufacture

Solution Approach 1:

The gap filler utilizes phase change of a compressible material from compressed state to expanded state to seal gaps. The material transitions from a compact form during installation to an expanded sealing form once deployed, automatically adapting to gap variations without requiring precise manufacturing tolerances

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The gap filler is designed to self-expand and self-seal gaps between server rack cabinets without requiring external power sources, manual adjustment, or complex installation mechanisms. The compressible material automatically expands to fill gaps when the seal is released, providing autonomous sealing functionality

Inventive Principle:

Principle #25Self-service

2Loss of energy

If gaps between server rack cabinets are sealed to prevent air mixing, then energy loss is reduced, but the complexity of installation increases

Engineering Contradiction:

Improveair leakage preventionVSAvoidgap filler structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The gap filler employs phase change of compressible material to transition between compact installation state and expanded sealing state, providing effective gap sealing with minimal structural complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The gap filler utilizes a flexible outer layer that can conform to various gap shapes and sizes between server rack cabinets. This flexible membrane structure provides effective sealing without requiring rigid or complex mechanical components

Inventive Principle:

Principle #30Flexible shells and thin films

3Loss of energy

If traditional gap filling materials are used, then air leakage is reduced, but the ability to reach tight spots and hard to reach areas is limited

Engineering Contradiction:

Improveair leakageVSAvoidinstallation accessibility

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The gap filler is designed with a nested structure where the compressible material is contained within an outer layer, allowing it to be inserted in a compact form through tight spaces and then expand in place to seal gaps that would be inaccessible to traditional rigid filling materials

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The gap filler is provided as separate insertable sections that can be individually placed into gaps between server rack cabinets. This segmentation allows the filler to reach tight spots and hard-to-access areas that would be impossible to reach with continuous or rigid sealing materials

Inventive Principle:

Principle #1Segmentation

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 self-expanding gap filler effectively reduces air leakage between hot and cold aisles, improving cooling efficiency and energy savings by maintaining the separation of air flows.

Implementation Method 1

The outer layer encapsulates the compressible material in a compressed state within the inner space. The seal is partially released to allow air to flow into the inner space of the outer layer to permit the compressible material to expand from the compressed state within the inner space of the outer layer to an expanded state within the inner space of the outer layer

Methodology Applied

Scientific EffectCompression and expansion of compressible material: Elasticity

Data Source

PatentUS12274037B2Self-expanding gap filler for decreasing air leakage between adjacent elements in a data center

Publication Date: 2025.04.08 BLUEMAMBA INC

AI summary

A data center having a hot aisle, a cold aisle, a row of server rack cabinets located between the cold aisle and the hot aisle, and a self-expanding gap filler located in a gap between adjacent elements in the data center is provided. The self-expanding gap filler includes a compressible material and a tubular outer member defining an inner space, the tubular outer member encapsulating the compressible material within the inner space. The compressible material is configured to expand from a compressed state within the inner space of the tubular outer member to an expanded state within the inner space of the tubular outer member in response to a seal being at least partially released within the tubular outer member to allow air to flow into the inner space of the tubular outer member, whereby the self-expanding gap filler at least partially fills the gap between the adjacent elements in the data center.