Stacked Heat Rejection Units for High-Density Data Center Cooling
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Solution Overview
Problem
Current heat rejection devices for data centers are limited by coil surface area, fan flow, and space constraints, restricting the quantity of cooling units that can be installed and affecting heat rejection density.
Innovation Solution
A heat rejection system with vertically stacked heat rejection units, central air passages, and an inlet duct to bring in fresh ambient air, reducing recirculation and increasing heat rejection density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heat rejection devices are installed in traditional horizontal configurations, then they occupy more building space, but heat rejection density is limited
Solution Approach 1:
The patent transitions from horizontal arrangement to vertical stacking of heat rejection units, utilizing the vertical dimension to increase heat rejection density without proportionally increasing building footprint. Multiple heat rejection units are stacked vertically to reject heat from multiple floors through a single rooftop location, thereby improving heat rejection density while minimizing ground area occupation.
Solution Approach 2:
The patent implements nested configuration where multiple heat rejection units are contained within a vertically stacked arrangement. Each heat rejection unit is nested within the overall vertical structure, with units from different floors being integrated into a compact stacked configuration that shares common structural and airflow pathways.
2Productivity
If coil surface area is increased to improve heat rejection, then device complexity and space requirements increase
Solution Approach 1:
The patent divides the heat rejection function into multiple separate heat rejection units, each with its own coil assembly. Instead of one large complex coil system, multiple smaller coil units are segmented and stacked vertically, with each unit handling heat rejection from a specific floor or zone, thereby reducing individual coil complexity while maintaining overall heat rejection efficiency.
Solution Approach 2:
The patent distributes coil surface area across multiple vertical levels rather than concentrating it in a single horizontal plane. By stacking heat rejection units vertically, the total coil surface area is distributed through the vertical dimension, allowing improved heat rejection efficiency without requiring a single large complex coil assembly.
3Productivity
If fan flow capacity is increased to improve heat rejection, then energy consumption and noise increase
Solution Approach 1:
The patent segments the fan system into multiple smaller fan units, each associated with a specific heat rejection unit. Instead of one large high-power fan, multiple smaller fans are distributed across the stacked units, allowing for more efficient airflow management and reduced energy consumption per unit while maintaining total heat rejection capacity.
Solution Approach 2:
The patent implements variable speed control and selective operation of fan units, allowing only the necessary number of fans to operate at any given time based on cooling demand. This partial action approach avoids the excessive energy consumption of running all fans at full capacity, while still achieving required heat rejection capacity when needed.
4Productivity
If recirculation is reduced to improve cooling efficiency, then fresh air intake requirements increase
Solution Approach 1:
The patent utilizes vertical airflow pathways through the stacked heat rejection units to create natural draft effects and improve air intake efficiency. By arranging units vertically with centralized air intake at the base and exhaust at the top, the system leverages buoyancy-driven flow in the vertical dimension to enhance cooling efficiency while managing fresh air requirements.
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 system enhances heat rejection density, allows for multi-floor data centers, maximizes server usage, and decreases recirculation, improving cooling efficiency.
Implementation Method 1
Heat rejection devices often transfer heat from the return fluid of the CRACs to a cooler medium, such as outside ambient air
Implementation Method 2
one or more central air passages configured to connect the first heat rejection unit to the second heat rejection unit
Implementation Method 3
a first heat rejection unit including a first set of fans and coils; a second heat rejection unit configured to be stacked on top of the first heat rejection unit, where the second heat rejection unit includes a second set of fans and coils
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A heat rejection system comprises a first heat rejection unit including a first set of fans and coils; a second heat rejection unit configured to be stacked on top of the first heat rejection unit, wherein the second heat rejection unit includes a second set of fans and coils; one or more central passages configured to connect the first heat rejection unit to the second heat rejection unit, wherein the one or more central passages separate the first heat rejection unit into at least a first section and a second section, wherein the first section includes a first fan and a first coil of the first set of fans and coils and the second section includes a second fan and a second coil of the first set of fans and coils; and an inlet duct configured to communicate with outside and receive fresh ambient air via an opening in the inlet duct, wherein the inlet duct is arranged below the first heat rejection unit and configured to divert the fresh ambient air to at least one of the first heat rejection unit or the second heat rejection unit to be exhausted outside.