Universal Fan System with Modular Airflow Channels
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Solution Overview
Problem
Existing cooling systems for electronic equipment are highly specific and inflexible, requiring extensive redesign for minor changes in components or their positions, leading to high R&D effort and costs, especially in customizable or low-volume systems.
Innovation Solution
A universal fan system with a modular design that separates cooling hardware from electronics, featuring a matrix of fan compartments, adjustable airflow channels, and a control system to optimize airflow based on different temperature and resistance scenarios, allowing for easy adaptation and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If highly specific cooling systems are designed for each electronic equipment configuration, then cooling performance is optimized for specific hardware, but R&D effort and cost increase significantly
Solution Approach 1:
The patent applies universality by designing a cooling system that can serve multiple electronic equipment configurations. The fan tray assembly is designed to work with different server types (e.g., 1U, 2U, 4U servers) and can accommodate various fan configurations (single fan, dual fan, quad fan) through a standardized interface and modular design, eliminating the need for separate cooling system designs for each hardware configuration.
Solution Approach 2:
The patent applies segmentation by dividing the cooling system into modular components: fan trays, fan compartments, and adjustable airflow channels. Each fan tray contains multiple fan compartments that can be independently configured, and the airflow channels can be adjusted to direct cooling air to different locations based on the specific hardware arrangement, allowing flexible adaptation without complete redesign.
2Reliability
If cooling systems are tightly integrated with electronic equipment design, then cooling efficiency is maximized for specific hardware, but flexibility and adaptability decrease
Solution Approach 1:
The patent applies dynamics by incorporating adjustable airflow channels that can be reconfigured based on different hardware arrangements. The channels include adjustable deflectors and movable partitions that allow the cooling system to adapt its airflow pattern dynamically, maintaining optimal cooling efficiency whether the server uses a standard configuration or has components relocated for customization or repair.
Solution Approach 2:
The standardized fan tray assembly design allows the same cooling component to be universally applied across different server configurations. The fan tray can accommodate various fan sizes and configurations, and the airflow channels can be adjusted to serve different heat-generating components, providing both universality and adaptability.
3Reliability
If extensive redesign is performed for minor component changes, then cooling requirements are met, but productivity and time-to-market decrease
Solution Approach 1:
The patent applies preliminary action by pre-configuring the fan tray assembly with multiple fan compartments and adjustable airflow channels that can accommodate various hardware arrangements. The modular design allows the cooling system to be prepared in advance to handle different configurations, so when component changes occur, the system can be adapted by simple reconfiguration rather than extensive redesign.
Solution Approach 2:
The patent applies parameter changes by allowing adjustment of airflow channel configurations, fan speeds, and channel blockages to optimize cooling for different hardware arrangements. These parameter adjustments can be made through software control or simple physical reconfiguration, enabling the system to meet cooling requirements for modified hardware without requiring complete redesign.
4Reliability
If different air cooling designs are implemented for different server types, then each system is optimized for its specific hardware, but manufacturing cost and complexity increase
Solution Approach 1:
The patent applies universality by creating a standardized fan tray assembly that can be manufactured once and used across multiple server types. The same fan tray design can accommodate 1U, 2U, and 4U servers, as well as different fan configurations, significantly reducing manufacturing complexity and cost compared to producing separate cooling systems for each server type.
Solution Approach 2:
The patent applies homogeneity by standardizing the fan tray assembly design across different server applications. The consistent design approach, standardized interfaces, and uniform component specifications enable economies of scale in manufacturing and simplify the supply chain, reducing overall manufacturing costs while maintaining system optimization through configurable parameters.
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
Significantly reduces R&D effort and costs by providing a flexible cooling solution that can be easily adapted to various hardware systems, improving design efficiency and thermal management across different scenarios.
Implementation Method 1
a fan 106 in each fan compartment 104 to move air through the housing 304
Implementation Method 2
a valve 105 in each fan compartment 104 to control air flow between fan compartments 104
Implementation Method 3
heat-generating components such as a processor 310 and a power control unit (PCU) 308
Implementation Method 4
cooling equipment, such as fans and other cooling components
Data Source
AI summary
Embodiments are disclosed of a fan module. The fan module includes a module housing having a module inlet and a module outlet. A fan compartment matrix is positioned within the housing to move air between the module inlet and the module outlet. The fan compartment matrix includes an M×N matrix of fan compartments, each fan compartment having an upstream side and a downstream side. A longitudinal air channel positioned between each pair of fan columns and a transverse air channel positioned between each pair of fan rows, the transverse air channel being fluidly coupled to the fan compartments between which it is positioned. A control chamber is positioned at each confluence of the at least one longitudinal air channel and the transverse air channel, the control chamber including one or more valves to control airflow between the longitudinal air channel and the transverse air channel. A fan is positioned in each fan compartment.