Staggered Funnel Panel for Evaporative Cooler Water Collection
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Solution Overview
Problem
Current indirect evaporative cooling systems for data centers face challenges with high piece part counts and labor-intensive assembly in their water collection systems, which complicate the efficient collection and reuse of water sprayed on heat exchangers.
Innovation Solution
A water collection system with a housing and panel assemblies featuring staggered funnels in a checkerboard pattern, reducing the number of parts and complexity, while ensuring effective water collection and redistribution with minimal airflow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a matrix of troughs with four or more rows and twenty or more columns is used to collect water, then water collection coverage is improved, but the piece part count and assembly complexity increase significantly
Solution Approach 1:
The patent merges multiple individual troughs into a single integrated panel assembly that functions as one piece. This panel assembly includes multiple funnels integrated into a unified structure with a common collection pan, eliminating the need for separate trough components while maintaining comprehensive water collection coverage across the heat exchanger surface.
Solution Approach 2:
The panel assembly serves multiple functions simultaneously: it acts as a collection surface, provides structural support, integrates funnel structures for water channeling, and includes a collection pan for water accumulation. This multi-functional design replaces what would otherwise require multiple separate components.
2Strength
If a welded assembly of matrix troughs is used, then structural integrity is improved, but the skill level required for assembly and manufacturing complexity increase
Solution Approach 1:
The water collection system is segmented into modular panel assemblies that can be independently manufactured and then easily installed. Each panel assembly is designed as a discrete unit with standardized dimensions and attachment features, allowing for simplified assembly without requiring welding skills. The modules can be connected using mechanical fastening methods.
3Reliability
If traditional water collection systems are used, then water collection function is provided, but weight and installation complexity increase
Solution Approach 1:
The panel assembly utilizes thin-walled construction with integrated funnels formed from sheet material. The design employs slender profiles and optimized wall thicknesses that provide sufficient structural strength for water collection while minimizing material usage and overall weight. The thin-film approach maintains functional integrity without excessive mass.
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 reduces the piece part count by two-thirds, lowers weight by 25%, and simplifies assembly, improving water capture efficiency and airflow while maintaining high water recovery rates.
Implementation Method 1
panel assemblies disposed within the interior region of the housing above the plurality of tube assemblies, each panel assembly being associated with a respective tube assembly to channel fluid to the tube assembly
Implementation Method 2
the outside of the air-to-air heat exchanger is sprayed with water, which further lowers the temperature of the outside air
Data Source
AI summary
A water collection system is provided for an indirect evaporative cooler. The water collection system includes a housing having an open bottom, a front wall, a back wall, and two end walls, which together define an interior region of the housing. The water collection system further includes a plurality of tube assemblies each extending through one of the front wall and the back wall of the housing and disposed within the interior region of the housing. The water collection system further includes a plurality of panel assemblies disposed within the interior region of the housing above the plurality of tube assemblies. Each panel assembly is associated with a respective tube assembly to channel fluid to the tube assembly. A method of collecting and distributing water within an indirect evaporative cooler configured to spray water on a heat exchanger is further disclosed.