Power Module Assembly With Top Cooling for Dense Data Center Layouts
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Solution Overview
Problem
The challenge of fitting increased power module density in limited data center space while maintaining effective cooling, as traditional installations require side-by-side placement and mechanical cooling systems, is addressed by positioning a top cooling module above the power module to optimize airflow management.
Innovation Solution
A prefabricated power module assembly with a top cooling module positioned above the power module, featuring a cold air interface, hot air interface, and a cooler, which includes a barrier to separate airflow paths and control airflow using dampers, enabling efficient cooling of heat-generating equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If power modules are installed side-by-side to fit limited data center space, then power module density increases, but cooling system installation space is insufficient
Solution Approach 1:
The cooling module is repositioned from a horizontal side-by-side arrangement to a vertical stacked arrangement above the power module. This dimensional change allows the cooling system to occupy vertical space rather than horizontal space, enabling increased power module density in the horizontal plane while maintaining adequate cooling capacity through vertical stacking.
2Reliability
If traditional mechanical cooling systems are installed with sufficient clearance, then cooling performance is maintained, but power module density decreases
Solution Approach 1:
By moving the cooling module to a vertical position above the power module, the design maintains necessary cooling clearance in the vertical dimension while maximizing horizontal space for power modules. This dimensional reorganization preserves cooling performance requirements without sacrificing power density.
Solution Approach 2:
The cooling module is positioned to nest vertically above the power module, creating a compact stacked configuration. This nesting arrangement allows the cooling system to be integrated into the vertical space above the power equipment, maintaining cooling effectiveness while minimizing the overall footprint and maximizing power module density.
3Area of stationary object
If top cooling module is positioned above power module to increase density, then space utilization improves, but airflow management complexity increases
Solution Approach 1:
The airflow management system is segmented into distinct cold and hot air interfaces with separate dampers for each. This segmentation allows independent control of cold air supply and hot air exhaust, simplifying the management of vertical airflow paths and enabling precise control over the cooling process despite the complex stacked configuration.
Solution Approach 2:
Dynamic control elements (dampers) are incorporated at both the cold air interface and hot air interface to adaptively manage airflow. These movable components allow the system to adjust airflow rates and distribution in response to varying thermal loads, simplifying airflow management under different operating conditions while maintaining the compact vertical arrangement.
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 configuration allows for efficient cooling of power modules in limited space, optimizing airflow management and enabling quick deployment or replacement, while maintaining cooling system performance and layout flexibility.
Implementation Method 1
a cooler (24) in the cooling module (14), the cooler (24) having an input (46) coupled to the hot air interface (42) and an output (48) coupled to the cold air interface (40)
Implementation Method 2
a cold air interface (40) configured to enable relatively cool air from the cooling module (14) to flow to the power module (12); a hot air interface (42) configured to enable relatively warm air from the power module (12) to flow to the cooling module (14)
Data Source
AI summary
A prefabricated power module assembly includes a cooling module, a power module, a cold air interface configured to enable relatively cool air from the cooling module to flow to the power module, a hot air interface configured to enable relatively warm air from the power module to flow to the cooling module, and a cooler in the cooling module. The cooler has an input coupled to the hot air interface and an output coupled to the cold air interface. The cooling module is positioned above the power module.