Two-Phase Coolant Distribution Architecture for Data Center Immersion Cooling
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Solution Overview
Problem
Existing data center cooling systems face challenges in managing high-power density electronic racks, particularly due to lack of redundancy and requiring significant tuning and control, which can lead to thermal overload and equipment failure.
Innovation Solution
A two-phase coolant distribution architecture with redundant design and pressure sensors on vapor return loops to control main cooling sources, ensuring balanced and adaptive cooling capacity across parallel condensing core units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing cooling systems are used for high-power density racks, then the system structure is simple, but thermal management reliability is insufficient due to lack of redundancy
Solution Approach 1:
The cooling system is divided into multiple independent parallel loops, where each loop contains its own condensing core unit, vapor return loop, and liquid supply loop. This segmentation creates redundant pathways for coolant flow, ensuring that if one loop fails, others can continue to provide cooling, thereby improving thermal management reliability without requiring a complete system redesign
Solution Approach 2:
The system incorporates redundant condensing core units and parallel cooling loops as preventive measures before failures occur. This redundancy acts as a cushion against potential single-point failures, ensuring continuous cooling operation even when components fail, thus improving reliability while accepting increased system complexity
2Productivity
If existing phase change cooling systems are deployed, then cooling capacity is provided, but significant tuning and control effort is required after deployment
Solution Approach 1:
Pressure sensors are installed on the vapor return loops to automatically monitor system conditions and provide feedback for control adjustments. This self-monitoring capability enables the system to automatically regulate its operation based on real-time pressure readings, reducing the need for manual tuning and control intervention while maintaining optimal cooling capacity
Solution Approach 2:
The system implements a feedback control mechanism where pressure sensors continuously monitor vapor return loop conditions and automatically adjust system operation. This closed-loop control reduces manual tuning requirements by enabling the system to self-regulate based on actual operating conditions, thereby improving ease of operation while maintaining cooling capacity
3Reliability
If single failure port designs are used, then device complexity is reduced, but system reliability deteriorates due to lack of redundancy
Solution Approach 1:
The cooling system is divided into multiple independent parallel loops with separate condensing core units, vapor return loops, and liquid supply loops. This segmentation eliminates single failure ports by creating independent pathways, so that a failure in one loop does not compromise the entire system, thereby improving reliability while managing complexity through modular design
Solution Approach 2:
Redundant condensing core units and parallel cooling loops are built into the system design as preventive measures before failures occur. This redundancy cushions against potential single-point failures, ensuring continuous operation even when components fail, thus improving reliability while accepting the necessary increase in system complexity
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 solution provides advanced thermal management with high system reliability, increased power efficiency, and compatibility with various data center architectures, effectively addressing thermal challenges in high-density rack environments.
Implementation Method 1
a two-phase distribution unit to distribute the liquid in two parallel loops to the load (e.g., an immersion cooling system) and return the vapor in parallel from the load
Implementation Method 2
The pressure sensors may control one or more main cooling sources to the core condenser units to ensure the cooling capacity is sufficiently delivered to the two phase distribution unit
Data Source
AI summary
In one embodiment, an immersion cooling system comprising one or more electronic devices submerged in a two-phase liquid coolant, a first cooling loop to provide cooling liquid to the immersion system, wherein the first cooling loop comprises a first condenser unit, a first liquid supply line, and a first vapor return line, and a second cooling loop to provide cooling liquid to the immersion system, wherein the second cooling loop comprises a second condenser unit, a second liquid supply line, and a second vapor return line. The apparatus further includes a first pressure sensor coupled to the first vapor return line, a second pressure sensor coupled to the second vapor return line and at least one main cooling source comprising a fluid control valve controlled based on the first pressure sensor and the second pressure sensor.