Abstract:
The present disclosure relates to a unit structure for use in forming a modular data center. The unit structure may have an elongated frame structure forming a rectangular-like subsystem, and may be adapted to be supported above a floor surface. At least one conduit may be integrated into the elongated frame structure for supplying a fluid to an area defined by the elongated frame structure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. Non-Provisional application Ser. No. 14/504,081, filed Oct. 1, 2014, which claims the benefit of U.S. Provisional Application No. 61/886,402, filed on Oct. 3, 2013. The entire disclosures of each of the above applications are incorporated herein by reference. 
     
    
     FIELD 
       [0002]    The present disclosure relates to data center systems and methods for constructing data centers, and more particularly to a modular, pre-fabricated data center structure that is able to be configured in a highly space efficient manner for shipping purposes and then easily deployed at a destination site to form a data center, and further which is readily modularly expandable to meet changing data center needs at the destination site. 
       BACKGROUND 
       [0003]    The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
         [0004]    As data center needs increase world-wide, there has been increasing interest in finding more cost effective ways to set up and construct data centers. Additional concerns are consistent quality of the data center components and the time required to construct the data center. These concerns are especially relevant when constructing data centers in countries other than the United States. Traditionally data centers have been constructed in “stick building” fashion completely at the selected data center site. This involves bringing all the raw materials out to the data center site, using large numbers of construction workers such as electrical contractors, welders, building construction workers and other skilled tradesmen to construct the data center structure from the raw materials shipped to the site. As will be appreciated, this construction approach can be quite costly. Maintaining quality of the finished data center structure can sometimes be challenging, typically requiring numerous inspections by various individuals as the construction process is on-going. Construction delays may be encountered when specific subcomponents or raw materials being used to construct the data center are not received at the building site according to the planned construction timetable. The need to separately ship independent building components (steel, cable trays, wall panels, etc.) to the site can also contribute significantly to the overall high cost of constructing a data center. Seasonal weather changes and delays brought on by inclement weather can also result in a lengthy and costly construction timeline for a data center structure. 
         [0005]    Additional concerns with data centers are the ability to easily and cost-effectively expand the data center as needs grow. With conventional data center structures that have been constructed using the “stick build” approach, expansion can sometimes be expensive and particularly time consuming. 
         [0006]    Accordingly, there is strong interest in reducing the cost of a data center structure as well as the time needed for its construction. Significantly reducing the overall construction cost of a data center structure and the time required to get a new data center up and running may make it feasible to set up data centers in various parts of the world where the cost of constructing a data center with the conventional “stick build” approach would make the endeavor cost prohibitive. 
       SUMMARY 
       [0007]    In one aspect the present disclosure relates to a unit structure for use in forming a modular data center. The unit structure may comprise an elongated frame structure forming a rectangular-like subsystem, and adapted to be supported above a floor surface. At least one conduit may be integrated into the elongated frame structure for supplying a fluid to an area defined by the elongated frame structure. 
         [0008]    In another aspect the present disclosure relates to a modular data center. The modular data center may comprise a plurality of unit structures arranged generally parallel to one another, the unit structures defining a volume and being supported elevationally above a floor by support elements. Each unit structure forms an elongated structure having a rectangular frame structure and a built in lighting fixture. 
         [0009]    In still another aspect the present disclosure relates to a modular data center comprising a plurality of unit structures arranged generally parallel to one another. The unit structures are adapted to be supported elevationally above a floor by support elements. Each unit structure forms an elongated structure having a rectangular frame structure and a plurality of deployable panels. The deployable panels are configured to be suspended below the unit structures in operative configurations to help form cold aisles elevationally below each one of the unit structures. The deployable panels can be retracted into stowed configurations for shipping. The deployable panels help to form hot aisles between adjacent pairs of the unit structures when the deployable panels are in their operative configurations. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. In the drawings: 
           [0011]      FIG. 1  is a perspective illustration of a plurality of modular, collapsible data center unit structures disposed adjacent one another to help form a data center, in accordance with one embodiment of the present disclosure; 
           [0012]      FIG. 2  is an enlarged perspective view of a portion of one of the data center unit structures of the present disclosure even more fully illustrating a plurality of foldable cable tray supports, along with one cable tray, that each unit structure incorporates; 
           [0013]      FIG. 2 a    is a perspective view of a portion of one form of pivoting mechanism that may be used to support the hangers, which involves the use of an elongated tubular support member which is able to rotate; 
           [0014]      FIG. 2 b    is an enlarged perspective view of the saddle-like strap shown in  FIG. 2 a    which may be used to help enable rotational movement of the elongated tubular support member shown in  FIG. 2   a;    
           [0015]      FIG. 3  is a perspective view of one of the data center unit structures shown in  FIG. 1  but with the unit structure in its collapsed configuration for shipping; 
           [0016]      FIG. 4  is a perspective view of two data center unit structures in their collapsed configurations and positioned back-to-back, which forms a highly compact package suitable for placement in a standard shipping container; 
           [0017]      FIG. 5  is a high level side view of a portion of a data center in which two of the data center unit structures are shown forming an elongated row, and further illustrating a modular penthouse exhaust structure that resides above the data center unit structures to facilitate the exhaust of hot air from hot air isles formed between rows of equipment racks positioned underneath the unit structures; 
           [0018]      FIG. 6  is an enlarged view of just circled portion  6  in  FIG. 5 ; 
           [0019]      FIG. 6 a    is a perspective view of a portion of one end of the data center illustrating how hot air from a hot air isle may be exhausted through the modular penthouse exhaust structure; 
           [0020]      FIG. 7  is a perspective view of modular cooling unit that may be used with the data center unit structures to help form a modular data center; 
           [0021]      FIG. 8  shows a perspective view of one of the modular cooling units arranged adjacent the ends of a plurality of the data center unit structures; 
           [0022]      FIG. 9  is a high level top view illustrating the components of the modular cooling unit shown in  FIG. 7 ; 
           [0023]      FIG. 10  is a high level front view of the modular cooling unit of  FIG. 9 ; 
           [0024]      FIG. 11  is a high level side view of the cooling unit of  FIG. 9  in accordance with arrow  11  in  FIG. 10 ; 
           [0025]      FIG. 12  is a high level perspective view of just a filter unit of the modular cooling unit; 
           [0026]      FIG. 13  is a high level perspective view of just a fan unit of the modular cooling unit; 
           [0027]      FIG. 14  is a high level perspective view of just a cooling module media unit of the modular cooling unit; 
           [0028]      FIG. 15  is another high level perspective view of the modular cooling unit but with its outer wall structure removed, and further with the wall structure surrounding one of the fan units removed; 
           [0029]      FIG. 16  further illustrates components that may be included within each of the modular cooling units; 
           [0030]      FIG. 17  is a perspective view of one modular cooling unit located adjacent to a plurality of the data center unit structures illustrating how hot exhaust (i.e., return) air from one of the hot isles may be returned to the modular cooling unit; 
           [0031]      FIG. 18  is a high level overhead view of a portion of a data center illustrating a plurality of modular sections that together form a “power hall” for a data center, and which are located adjacent to a plurality of the data center unit structures; 
           [0032]      FIG. 19  illustrates a modular power supply unit for constructing the power hall shown in  FIG. 18 ; 
           [0033]      FIG. 20  illustrates a modular power cabinet unit for use in constructing the power hall shown in  FIG. 18 ; 
           [0034]      FIG. 21  shows a modular UPS unit for use in constructing the power hall shown in  FIG. 18 ; 
           [0035]      FIG. 22  shows a modular PDU unit for use in constructing the power hall shown in  FIG. 18 ; 
           [0036]      FIG. 23  is an overhead view of one exemplary layout for a data center that makes use of two halls separated by a modular office/storage area and a modular water treatment unit; 
           [0037]      FIG. 24  is a perspective view of another embodiment of the unit structure; and 
           [0038]      FIG. 25  is a perspective view of a portion of the unit structure of  FIG. 24  illustrating a centrally located cable tray. 
       
    
    
     DETAILED DESCRIPTION 
       [0039]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
         [0040]    Referring to  FIG. 1  there is shown a portion of a modular data center facility  10  incorporating a plurality of modular, collapsible data center unit structures  12  (hereinafter simply “unit structures  12 ”) for forming a rapidly deployable data center. Each of the unit structures  12  forms an elongated structure which may be used to channel both cold air from one or more air conditioning systems through a cold aisle  15  which separates parallel rows of equipment racks  14 , as well to help channel hot air from a hot aisle. Each unit structure  12  is adapted to be supported by structural support columns  16  at a predetermined height above a floor  18  of the data center facility  10 .  FIG. 1  illustrates a plurality of the unit structures  12  positioned in side-by-side fashion. Adjacent ones of the unit structures  12  are further spaced apart a predetermined distance. This spacing forms hot aisles  17  between adjacent ones of the unit structures  12 . 
         [0041]    With further reference to  FIG. 1 , the modular data center facility  10  may also include one or more modular penthouse exhaust structures  20  for receiving hot air from the hot aisles  17  and exhausting the hot air from the modular data center facility  10 . The modular penthouse exhaust structures  20  receive the hot air flow from the hot aisles  17  through openings  24  in ceiling panels  26  of the unit structures  12 . This feature will be explained in greater detail in the following paragraphs. A plurality of bridging ceiling panels  26   a  are also used to bridge the spacing between adjacent ones of the unit structures  12 , and thus ensure that hot air being drawn out from the hot aisles  17  is exhausted through the openings  24 . 
         [0042]    Referring to  FIG. 2 , one of the unit structures  12  is shown in greater detail. In addition to the ceiling panel  26 , each unit structure  12  has a frame structure  28  that supports a plurality of the ceiling panels  26  to form a roof-like structure. A perimeter frame structure  30  may be coupled to the structural support columns  16 . The perimeter frame structure  30  may be used to support collapsible (i.e., foldable) panels  32  to help maintain cold air from air conditioning systems within the cold aisles  15  between adjacent rows of equipment racks  14 . The perimeter frame structure  30  also may include a plurality of pivotally secured hangers  34  and  36  that are supported from the frame structure  30 . Hangers  34  in this example are supported from separate cross members  33  and are able to pivot into the orientation shown in  FIG. 2  for use. Hangers  34  may have a plurality of cable trays  38  secured thereto and hangers  36  may likewise have a plurality of cable trays  40  secured thereto. Cable trays  38  and  40  may be used to support a variety of different types of cables such as network cables, power cables, etc., that need to be routed through the data center facility  10  to equipment components mounted in the rows of equipment racks  14 . A roof panel  42  may also be secured to the perimeter frame structure  30 . Roof panel  42  forms a partition which further helps to channel cold air from one or more air conditioning systems through the cold aisle  15  formed between adjacent rows of equipment racks  14 . 
         [0043]    With brief reference to  FIG. 2 a   , a portion of one of the hangers  36  is shown. The hanger  36  may be representative of, or identical, to the construction used for the hangers  34 . The ability of the hanger  36  to pivot is achieved, in one example, by using a round, rigid, tubular, elongated support member  36   a,  which may be supported for rotational movement at its opposing ends by a saddle-like bracket  36   b,  where the saddle-like bracket  36   b  is fixedly secured to a portion of the perimeter frame structure  30  by suitable fasteners (not shown). The saddle like bracket  36   b  is also shown in  FIG. 2 b   . Of course any other suitable hinge or hinge-like structures could be implemented to enable pivoting motion of the hanger  36 . 
         [0044]      FIG. 2 a    also shows that the hanger  36  may include a plurality of depending structural members  36   c  which may support the cable trays  40 . The depending structural members  36   c  may be fixedly secured to the elongated support member  36   a  so as to be able to rotate with the elongated support member  36   a,  and thus be able to present the trays  40  in an operative position below the perimeter frame structure  30  or in a stowed orientation. One or more braces  36   d  may be used to brace the hanger  36  in its operative position. The braces  36   d  may each be secured at one end to the perimeter frame structure  30  by suitable brackets  36   e  that enable pivoting motion thereof, and at their opposite ends to the depending structural members  36   c.  This enables the braces  36   d  to be pivoted upwardly into stowed configurations once detached from the structural members  36   c.  Still, the braces  36   d  are able to be quickly and easily secured to the structural members  36   c  of the hanger  36 , to brace the hanger  36  once the hanger  36  is lowered into its operative position. It will also be appreciated that the hangers  36 , as well as the hangers  34 , may be constructed from suitable structural supports and brackets to permit their easy removal from the perimeter frame structure  30 , instead of a folding motion. Depending on how many cable trays  38  and  40  are employed, and the overall dimensions of the unit structure  12 , it may be helpful or necessary to have the hangers  34  and or  36  supported by structure that is removable completely from the perimeter frame structure  30  when the unit structure is prepared for shipping. 
         [0045]    With reference to  FIGS. 5, 6 and 6   a , one of the modular penthouse exhaust structures  20  is shown from one end thereof. It will be appreciated that, in practice, a plurality of the modular penthouse exhaust structures  20  will be used to form an elongated channel  46  into which hot air  17   a  from the hot aisles  17  may be drawn into with the assistance of a plurality of opposing exhaust fans  44 . In one embodiment each modular penthouse exhaust structure  20  may include a total of six exhaust fans  44  arranged as two opposing rows of three fans. With further reference to  FIG. 1 , the openings  24  in the ceiling panels  26  may also have positioned therein modulated louver assemblies  48  that may be electronically modulated to tailor the flow of hot air from the hot aisles  17  that may be drawn into the penthouse exhaust structures  20 . Suitable air flow and/or temperature control monitoring systems (not shown) may be provided for this purpose. 
         [0046]    Referring to  FIG. 3 , one of the unit structures  12  is shown in its collapsed configuration. The unit structure  12  has the hangers  34  and  36  pivoted into a stowed position where they are held such that they do not protrude below panel portions  32   a  of panels  32 . Panels  32  are also pivoted such that they extend parallel to the ceiling panels  26 . In the collapsed configuration the unit structure  12  forms an elongated, relatively narrow configuration with the hangers  34  and  36 , as well as the cable trays  38  and  40 , tucked up between the panel portions  32   a.  This configuration also forms a highly space efficient configuration from a shipping and packaging standpoint. Any suitable locking structure may be used in connection with the panels  32  to hold the panels  32  in their collapsed configuration, such as elongated structural beams (not shown) that may be physically connected to select portions of the panels  32  and the perimeter frame structure  30 .  FIG. 4  illustrates a pair of the unit structures  12  in their collapsed configurations positioned back-to-back. Each of the unit structures  12 , when in its collapsed configuration, may have dimensions of approximately 12192 mm (40.0 feet) in overall length by 3658 mm (12.0 feet) in width and 2848 mm (5 feet and 5.22 inches) in height. The back-to-back positioned pair of unit structures  12  in  FIG. 4  may have overall dimensions of about 12192 mm (40 feet) in length, 3658 mm (12 feet) in width and 2848 mm (9 feet and 4.13 inches) in overall height. The collapsed configuration enables a pair of the unit structures  12  to be efficiently packaged for shipping. 
         [0047]      FIG. 7  illustrates a modular cooling unit  50  that may be used to help form the modular data center facility  10  of  FIG. 1 . It will be noted that the modular cooling  50  may have dimensions of about 13761 mm (45 feet) in length, about 7315 mm (24 feet) in width and about 3500 mm (11 feet and 5.8 inches) in overall height. As such, the cooling module unit  50  is very similar in overall dimensions to the back-to-back pair of unit structures  12  shown in  FIG. 4 , which again facilitates shipping in a standardized shipping container. 
         [0048]    In  FIG. 8  one modular cooling unit  50  can be seen arranged so that its major length extends perpendicular to the major length of the unit structures  12 , and such that it is positioned adjacent one of the ends of the unit structures  12 . This enables the modular cooling unit  50  to supply cold air to the cold aisles  15  formed by a plurality of the unit structures  12 . 
         [0049]    With reference to  FIGS. 9-11 , each modular cooling unit  50 , in one embodiment, may form an evaporative (i.e., adiabatic) cooling unit that includes a filter unit  52 , a media unit  54 , a fan unit  56 , and may draw on the order of 900 kW.  FIGS. 12-14  further illustrate these components. Each fan unit  56  may include a plurality of fans  56   a,  and in one embodiment a total of twelve such fans  56   a  configured in three separate cabinets  56   b  as shown in  FIG. 15 .  FIG. 15  further illustrates that the cabinets  56   b  each may have an isolated access through a door  56   c.    
         [0050]      FIG. 16  illustrates that the media unit  54  may include three independent evaporative cooling modules  54   a - 54   c  having four cooling stages each. A DX coil and dampers  60  may optionally be included. The filter unit  52  may include a plurality of filters  52   a,  an electronically actuated return air damper  52   b  for controlling a return air flow into the modular cooling unit  50 , and an electronically actuated outside air louver and damper  52   c  for controlling the flow of outside (ambient air) drawn into the cooling unit  50 . 
         [0051]      FIG. 17  illustrates how hot air  17   a  in the hot air isles  17  may be returned within an area  64  formed between the ceiling panels  26 / 26   a  (te panels  26 / 26   a  being visible only in  FIG. 1 ), the bridging ceiling panels  26   a,  and the roof panels  42  of the unit structures  12  as “return” air through the return air dampers  52   b  to the modular cooling unit  50 . Cool air  62  is supplied into each of the cold aisles  15  by the modular cooling units  50 , which are able to draw in outside air  63 . 
         [0052]      FIG. 18  illustrates one embodiment of a modular “power hall”  70  that may be used in connection with the unit structures  12  to form the modular data center facility  10 . With additional reference to  FIGS. 19-22 , the modular power hall  70  may be made up of one or more modular power supply units  72  ( FIG. 19 ), one or more modular power cabinet units  74  ( FIG. 20 ), one or more modular UPS (uninterruptible power supply) units  76  and one or more modular PDU (power distribution unit) units  78 , as well as any other type of power component or subsystem.  FIG. 18  also shows a plurality of electrical bus bars  80  that may be used to connect the various components in each of the modular units  72 - 78  as needed to distribute power. 
         [0053]    The modular power supply units  72  may each include a main bus, for example a 5000 A main bus for supplying 100 kA at 480V. A plurality of main breakers and distributed breakers may also be included along with a suitable power control system and a power quality meter. 
         [0054]    The modular power cabinet units  74  may each include a 1600 A bus main bus for delivering 65 kA at 480V. Power breakers and distribution breakers may be configured as needed for specific applications. 
         [0055]    The modular UPS units  76  may each include parallel 400 kVA/400 kW modules to provide 750 kW of backup power. However, it will be appreciated that the UPS units  76  may be configured as needed to suit a specific application. 
         [0056]    Each of the modular PDU units  78  may be configured to provide 300 kVA 480/208/120V, or a different selected electrical output. Load distribution breakers may also be mounted in cabinets (not shown) that are in turn mounted to the sides of a frame of each PDU contained in the modular PDU unit  78 . 
         [0057]    Each of the modular units  72 - 78  may have similar or identical dimensions. In one embodiment the dimensions of the modular units  72 - 78  are identical with a length of 12192 mm (40 feet), a width of 3658 mm (12 feet) and a height of 3500 mm (11 feet and 5.8 inches). Obviously these dimensions may be varied slightly if needed. In this example, the modular units  72 - 78  may have length and width dimensions that are the same as the unit structures  12 . These dimensions enable shipping of the modular units  72 - 78  in conventional shipping containers. 
         [0058]    With brief reference to  FIG. 21 , each of the modular units  72 - 78  may include a frame structure  73  having one or more of components secured thereto such as a floor  73   a  and one or more wall portions  73   b.  The modular units  72 - 78  are also rapidly deployable when they are received at the destination site. The modular configuration of the units  72 - 78  allows for easily expanding the power supply capabilities of the power hall  70  as data center needs grow. 
         [0059]      FIG. 23  shows an overhead view of one example of an implementation of the modular data center facility  10 . The unit structures  12  are grouped into two halls, “Hall A” and “Hall B”, separated by a modular office/storage section area  80 . A modular water treatment section  82  may include water treatment equipment. Rows  84  of modular cooling units  50  may be arranged adjacent the rows of unit structures  12 . A row of modular penthouse exhaust structures  20  (not shown in  FIG. 23 ) may extend over a hallway area  86 , perpendicularly to the unit structures  12 , to interface with the hot aisles  17  adjacent the unit structures  12 . A modular room  86  may be included for other data center or office equipment. 
         [0060]    Referring to  FIG. 24 , a unit structure  100  is shown in accordance with another embodiment of the present disclosure. The unit structure  100  is this example also has additional structural columns  102  that may be used to help form a hot aisle with one or more doors at opposing ends of the unit structure  100 . 
         [0061]    The unit structure  100  can also be seen in  FIG. 25  to include a central, elongated tray  104  that runs a substantial portion of a full length of the unit structure  100 . The central, elongated tray  104  may include a pair of curving tray portions  106  that enable cables to be fed out from the central, elongated tray  104 . The central, elongated tray  104  and the curving tray portions  106  may each include a plurality of posts  108  to help retain cables within the trays  104  and  106 . 
         [0062]    It will be appreciated that the various embodiments of the present disclosure may incorporate built in lighting fixtures, as well as one or more lengths of built in conduit for the delivery of water or a different fire suppression agent. The cable trays  38 ,  40  and  104  may be used to divide and route specific types of cabling (i.e., optical, power, network, etc.) depending on user requirements or preferences. 
         [0063]    The various embodiments of the modular data center facility  10  enable the various modular components that are used to form the data center to be easily shipped to a destination site and constructed in a desired configuration. The modular components the data center facility  10  can be rapidly deployed so that a fully functioning data center can be constructed much more quickly than a conventional “stick built” data center structure. 
         [0064]    While various embodiments have been described, those skilled in the art will recognize modifications or variations which might be made without departing from the present disclosure. Any dimensions given on the drawings hereof are intended to be merely examples of suitable dimensions, and such may be modified as needed to meet the needs of specific applications. The examples illustrate the various embodiments and are not intended to limit the present disclosure. Therefore, the description and claims should be interpreted liberally with only such limitation as is necessary in view of the pertinent prior art.