Abstract:
The present invention is directed to apparatus and methods for cooling computer servers and/or electrical equipment in a rack device for data centers or telecommunication centers.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention generally relates to apparatus and methods for cooling electronic devices. More particularly, the present invention relates to apparatus and methods for cooling heated air emanating from electronic equipment to prevent overheating thereof. 
         [0002]    It is generally well known that electronic devices such as computers generate heat when they are running, and that the device can be damaged should the temperature of the device be allowed to rise above a certain threshold. It is therefore important to ensure the device has a way of dissipating the generated heat so as to prevent overheating thereof. 
         [0003]    Many of today&#39;s industries and businesses require a host of computer servers and electrical equipment that are located in what is referred to as a server room or telecommunication equipment room. Individual servers or other electronic devices may be arranged in a server rack which typically comprises a frame having a plurality of shelves arranged in vertically spaced relationship with each server or other electronic device positioned upon a respective shelf. The shelves are vertically spaced from each other to allow air to circulate between each server in a rack. 
         [0004]    Manufacturers of the servers or other electronic devices make the housing with openings allowing air to travel through the device. In this way, heated air generated from the electronic components located within the housing is allowed to escape through the openings in the housing. Some electronic device manufacturers incorporate fans near the housing openings to actively draw the heated air out of the housing. Other heat management strategies may be utilized on or adjacent the housing such as fins or the like which act as heat sinks to help dissipate heat from the device. 
         [0005]    The problem of electronic device heat management becomes more troublesome and acute when dealing with very large dedicated server rooms or rooms with high density equipment which generate significant amounts of heat. In these settings, auxiliary heat management tactics are required such as using evaporator/condenser type air conditioning units to cool the air within the server room. Such air conditioning units are referred to in the industry as “CRAC” units, which stands for “Computer Room Air Conditioning”. While CRAC units may do the job of keeping the servers at a safe operating temperature, they are not very efficient in that they require a lot of electricity to keep the entire volume of the server room air cool. Maintaining the air in a large server room cool can thus be a significant, ongoing cost which can increase exponentially as more server racks are added to the room, rack densities are increased and/or the room size is expanded. For industries such as telecommunication companies which require server rooms the size of football fields, the operational costs of running CRAC units becomes financially unworkable and alternative, cheaper cooling strategies are necessary. 
         [0006]    In response to the need for more efficient cooling strategies, cooling units and assemblies have been proposed which are placed in close proximity to the individual servers. In this strategy, the heated air being ejected from the device housing is cooled prior to it being allowed to mix with the ambient air in the room. Examples of such units and assemblies may be seen in the following patents:
   U.S. Pat. No. 7,380,657 issued to Chu et al on Nov. 9, 2010   U.S. Pat. No. 7,905,105 issued to Fair et al on Mar. 15, 2011   U.S. Pat. No. 7,385,810 issued to Chu et al on Jun. 10, 2008   
 
         [0010]    While the prior art has provided various apparatus and approaches for cooling server racks and server rooms, a need remains for a server rack/room cooling solution which is robust and reliably operates with little to no chance of harming the electronic components should a coolant leak from the cooling lines, has improved operating efficiency over prior art systems, and is readily customizable to a variety of loaded server rack configurations and heat loads. The present invention provides apparatus and methods which successfully addresses the above performance objectives. 
       SUMMARY OF THE INVENTION 
       [0011]    Server racks generally comprise a tall, rectangular metal frame having vertically spaced shelves with the rack being open at the front and back. A series of racks are typically positioned in side-by-side relation in spaced rows. The rack open front provides access to the front of the servers while the open back provides access to the back of the servers. As explained above, server housings include openings allowing air to pass therethrough to assist with extracting heat from the server. 
         [0012]    The present invention provides in a first aspect thereof a cooling door adapted to be removably mounted to the rear opening of a server rack. Although the preferred embodiment is a hinged door, it is understood that the word “door” as used herein is to be broadly interpreted to mean any type of connection so long as the door may be moved between a substantially closed and open positions relative to the server rack. Even further, the door may instead be free standing or attached by any means to a separate frame or the like that may be positioned next to but is not necessarily connected to the server rack (e.g., a frame on lockable caster wheels that may be rolled adjacent the rack). 
         [0013]    The cooling door includes a protective cooling door cover preferably formed of sheet metal having air openings which may take the form of open area hexagonal holes and/or screen-type walls allowing unrestricted air flow therethrough. The door cover is preferably connected to the server rack via a hinged connection allowing the cooling door to pivot between open and closed positions. In the open position, the server rack rear opening is accessible to service or otherwise handle the servers on the rack shelves as needed. In the closed position, the cooling door cover extends across substantially the entire height and width of the rack rear opening. 
         [0014]    A rectangular heat exchanger mounting frame is provided having first and second side frame members with a top frame member and bottom frame member extending therebetween to define a rectangular opening. The heat exchanger mounting frame is mounted between the door cover and the rear opening of the server rack. In a preferred embodiment, the mounting frame connects to the door cover in the proximity of the door cover hinges such that the loaded frame weight is not carried by the door cover but rather is supported at or adjacent to the location of the door hinge axis. Separating the mounting frame weight load from the major surface area of the door cover minimizes physical load stress on the cooling door cover which has beneficial effects such as reducing door cover wear and vibrations, for example. A separate hinge stiffening bar may be provided to extend along the length of the hinged edge of the door cover and to which the mounting frame may directly attach which provides further cooling door strength and stability. 
         [0015]    At least one heat exchanger module is provided for removable attachment to the heat exchanger mounting frame. In a preferred embodiment, each heat exchanger module is first mounted to a respective tray which in turn is mounted to the heat exchanger mounting frame. The tray includes an array of fan openings in which a respective fan or, if no fan is required at a particular tray opening location, a cover may be removably mounted. The fans operate to help increase the CFM (cubic feet per minute) by drawing and direct air from the servers through the heat exchangers to cool it, maximizing the heat exchanger&#39;s capacity and then directing the cooled air through the openings in the door cover and into the server room. 
         [0016]    In the preferred embodiment, three tray/heat exchanger modular units of substantially the same size and shape may be individually, removably mounted in vertically spaced relation to one another to the heat exchanger mounting frame. In a preferred embodiment, the removable mounting means comprises a plurality of longitudinally spaced openings formed through the side frame members of the mounting frame wherethrough a key-hook, pin, bolt, or similar mounting component on the tray may removably pass and be secured. It is preferred that mounting means such as a key-hook or pin be used which does not require any tools. 
         [0017]    The number and arrangement of individual servers in a server rack may vary at any given time depending on the needs of the business. When racks are not fully loaded with servers there are empty shelves within the rack. Understanding that it is an inefficient use of energy to have heat exchangers located and operating at empty shelves, the present invention permits a technician to very quickly and optimally with no tools alternately mount and remove individual heat exchanger modules on the cooling door mounting frame such that the heat exchangers are positioned only at those locations where servers are located within the rack. In this regard, it will be appreciated that the technician may visually identify where to place the heat exchanger module on the mounting frame (i.e., directly in front of server-occupied rack shelves), and then align and pass the mounting components (e.g., key-hooks or pins) on the heat exchanger unit with and through the openings on the mounting frame that align with the desired identified location. 
         [0018]    When the rack is full of servers, the maximum number of heat exchanger units or modules are mounted to the cooling door counting frame. Should certain racks lack a server, the heat exchanger adjacent those shelves may be removed from the mounting frame. In a preferred embodiment, the empty location on the mounting frame may be replaced with a closed tray (no fans and no openings thereon) or other closed panel (mounted in the same removable manner as the tray/heat exchanger unit) which acts to direct any warm air passing from the empty rack shelves to the next adjacent heat exchanger module. It will thus be appreciated that the present system allows the cooling door to be quickly and easily customized “on the fly” by the customer (with no special technician training needed) to accommodate intermittent changes in server numbers and locations within a rack to thereby minimize energy usage and maximize operating efficiencies. This modularity also makes maintenance or replacement of heat exchanger modular units quick to minimize downtime. 
         [0019]    In yet a further embodiment of the invention, variations in rack heights may be accommodated by incorporating a movable shroud located at the top of the door cover which may be moved up or down on the door cover as needed. For example, the shroud may be moved to cover the top segment of the door cover to extend it to match the rack height. This allows one door design to transcend multiple rack heights and rack manufactures. Example: a design can allow mounting to 42 U through 44 U heights and accommodate variation between manufactures rack heights. 
         [0020]    In a preferred embodiment, the heat exchangers are micro-channel heat exchangers and refrigerant (e.g., R134A) is the coolant which travels through supply and return lines positioned above each row of server racks. Individual rack refrigerant supply and return lines are directed along the hinge side of the cooling doors and connect to a respective heat exchanger via quick connect swivel couplings. The refrigerant will flash to a gas at room temperature and there is thus no fear of damaging the servers should a leak occur in the supply or return lines as would be possible if the coolant used was water, for example, as is used in many prior art cooling systems. 
         [0021]    A further benefit of having removable mounting of the heat exchanger modules to a separate door mounting frame is that the door cover, which includes the door handle, may be attached to the rack in either a right opening or left opening door orientation. The door cover and mounting frame (which have been previously connected together as explained above) may thus be first connected to the rack in either a left opening or right opening manner by simply rotating the door 180° as necessary to achieve the desired orientation. Once the door cover with mounting frame is attached to the rack, the desired number of tray/heat exchanger units are removably mounted to the mounting frame. The ability to removably mount the tray/heat exchanger units to the mounting frame is not dependent on which 180° orientation of the door cover and mounting frame is chosen. This is due to the configuration of the heat exchanger/mounting frame cooperative mounting components which, as stated above, are preferably in the form of a plurality of longitudinally spaced openings formed in each side frame member of the mounting frame and key-hooks extending from the tray/heat exchanger unit. The openings in the mounting frame are preferably the same configuration regardless of which 180° orientation is chosen for the door cover and mounting frame. Each tray/heat exchanger unit may thus be removably mounted to the mounting frame by passing the key-hooks through respective openings in the mounting frame side members. Once inserted and manually released, gravity secures and maintains the tray/heat exchanger unit on the mounting frame by virtue of the key-hook hanging within the respective opening. 
         [0022]    Further operating efficiencies may be realized by electronically controlling the fans to turn on, off and/or change speeds in response to the sensed heat load at any given time or time intervals using temperature or other suitable sensors. 
     
    
     
       DESCRIPTION OF THE DRAWING FIGURES 
         [0023]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become apparent and be better understood by reference to the following description of the invention in conjunction with the accompanying drawing, wherein: 
           [0024]      FIG. 1  is a perspective view showing an environment having a row of server racks with cooling doors mounted thereto in accordance with an embodiment of the invention; 
           [0025]      FIG. 2  is a perspective view of a door cover of the cooling door; 
           [0026]      FIG. 3  is a perspective view of a mounting frame and hinge stiffening bar of the cooling door; 
           [0027]      FIG. 3A  is an enlarged detail view of the circled segment “A” of  FIG. 3 ; 
           [0028]      FIG. 3B  is an enlarged detail view of the circled segment “B” of  FIG. 3 ; 
           [0029]      FIG. 4  is an exploded view of a heat exchanger modular unit according to a preferred embodiment of the invention; 
           [0030]      FIG. 5  is a perspective view of a cooling door showing the heat exchanger side thereof which would face the rear of the rack to which is mounts; 
           [0031]      FIG. 5A  is an enlarged detail view of the circled segment “A” of  FIG. 5 ; 
           [0032]      FIG. 5B  is an enlarged detail view of the circled segment “B” of  FIG. 3 ; 
           [0033]      FIG. 5C  is an enlarged perspective view of  FIG. 5 ; 
           [0034]      FIG. 6  is an elevational view of the heat exchanger side of the cooling door; and 
           [0035]      FIG. 7  is an elevational view of the door cover side of the cooling door. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0036]    Referring now to the drawing figures, there is seen in  FIG. 1  a server rack and server room cooling system having a row  10  of server racks  12  which may be located in a dedicated server room (not shown). Although a single row of seven server racks  12  is shown in  FIG. 1 , it will be readily appreciated that the invention may be used to cool heated air rejected from any number of server racks placed in any arrangement. 
         [0037]    It is seen that each server rack  12  generally comprises a tall, rectangular metal frame having vertically spaced shelves “S” with the rack being open at the front “F” and back or rear “R”. A series of racks  12  are typically positioned in the side-by-side relation shown with multiple rows in spaced, parallel relation to one another. Very large server rooms can have hundreds if not thousands of server racks. The rack open front “F” provides access to the front of the servers (the servers themselves are not shown) while the open rear “R” provides access to the back of the servers. As explained above, server housings include openings allowing air to pass therethrough to assist with extracting heat from the server. 
         [0038]    The present invention provides in a first aspect thereof a cooling door indicated generally at  14  adapted to be removably mounted to the rear opening “R” of a server rack  12 . The cooling door  14  includes a protective cooling door cover  16  ( FIG. 2 ) preferably formed of sheet metal and having screened surfaces  16   a  having a pattern of closely spaced openings allowing substantially unrestricted air flow therethrough. The door cover  16  is connected to the server rack  14  via one or more hinges  18  ( FIGS. 5A and 5C ) which may be secured at openings  16   b  formed adjacent side edge  16   c  of door cover  16  ( FIG. 2 ). Opposite door cover side edge  16   d  includes an opening  16   e  for attachment of a handle  20 . The hinged connection allows the cooling door  14  to pivot between the open position (server rack  12  at the right end of row  10  in  FIG. 1 ), and the closed position (all other server racks  12  in row  10 ). In the open position, the server rack rear opening “R” is accessible to service or otherwise handle the servers on the rack shelves “S” as needed. In the closed position, the cooling door cover  16  extends across substantially the entire height “H” and width “W” of the rack rear opening “R”. 
         [0039]    As seen best in  FIG. 3 , a rectangular heat exchanger mounting frame  22  is provided having first and second side frame members  24  and  26  with a top frame member  28  and bottom frame member  30  extending therebetween to define a rectangular opening  32 . The heat exchanger mounting frame  22  is mounted inside the door cover  16  as will be explained below. In a preferred embodiment, the mounting frame  22  connects to the door cover  16  in the proximity of the door cover hinges  18  such that the loaded frame weight is not carried by the major surface area of the door cover  16  but rather is supported at or adjacent the location of the door hinge axis X-X. Separating the mounting frame  22  weight load from the major surface area of the door cover  16  minimizes physical load stress on the cooling door cover  16  which has beneficial effects such as reducing door cover wear and vibrations, for example. A separate hinge stiffening bar  34  may be provided to extend along the length of the hinged edge of the door cover  16  by aligning and passing screws through holes  16   b  and  34   b.  The mounting frame  22  may directly attach to stiffening bar  34  via angled brackets  36   a  and  36   b  ( FIGS. 3 and 3B ) which provides further cooling door strength and stability. 
         [0040]    As seen in  FIG. 4 , at least one heat exchanger modular unit  40  is provided for removable attachment to the heat exchanger mounting frame  22 . In a preferred embodiment, each heat exchanger module  40  is first mounted to a respective tray  42  which in turn is mounted to the heat exchanger mounting frame  22  via brackets  44 . 
         [0041]    A heat exchanger  50 , preferably an aluminum micro-channel heat exchanger coil, having supply and return lines  52  and  54 , respectively, is mounted to tray  42  via any suitable mounting components. For example, tray  42  is seen to include side walls  42   a  and  42   b  having notches  42   c  wherein heat exchanger supply and return headers  52   a,    54   a  may fit, respectively, with screws  42   d  passing through aligned holes  43 , 51  in the tray side walls and heat exchanger, respectively. 
         [0042]    Tray  42  is seen to include an array of fan openings  46  in which a respective fan  48  or, if no fan is required at a particular tray opening location  46  due to the absence of a server at that location, a cover  49  may be removably mounted. The fans  48  operate to help draw and direct air from the servers in the rack  12  through the heat exchanger  50  to cool the air, and then direct the cooled air through the openings  16   a  in the door cover  16  and into the server room. 
         [0043]    Referring now also to  FIGS. 5-7 , in the preferred embodiment, at least three heat exchanger modular units  40   a,    40   b  and  40   c  of substantially the same size and shape may be individually, removably mounted in vertically spaced relation to one another to the heat exchanger mounting frame  22 . In a preferred embodiment, the removable mounting means comprises a plurality of longitudinally spaced openings  24   a,    26   a  formed through respective side frame members  24  and  26  of the mounting frame  22  wherethrough the head of a key-hook  60  ( FIG. 4 ,  5 B) or other suitable mounting component on the tray  42  may removably pass and be secured. It is preferred that mounting means such as a key-hook head be used which may removably engage the respective opening  24   a,    26   a  without requiring any tools. 
         [0044]    The number and arrangement of individual servers in a server rack  12  may vary at any given time depending on the needs of the business. When racks are not fully loaded with servers there are empty shelves “S” within the rack. Understanding that it is an inefficient use of energy to have heat exchangers located and operating at empty shelves, the present invention permits a technician to very quickly and optimally with no tools mount or remove individual heat exchanger modular units  40   a,    40   b  and  40   c  on the cooling door mounting frame  22  such that the heat exchanger modular units are positioned only (or mostly only) at those locations where servers are located within the rack  12 . In this regard, it will be appreciated that the technician may visually identify where to place the heat exchanger modular unit  40  on the mounting frame  22  (i.e., directly in front of server-occupied rack shelves), and then align and pass the mounting components (e.g., key-hooks  60 ) on the heat exchanger modular unit  40  with and through the selected openings  24   a,    26   a  on the mounting frame  22  that align with the desired identified location. 
         [0045]    When the rack is full of servers, the maximum number of heat exchanger modular units  40  are mounted to the cooling door counting frame  22 . Should certain rack shelves “S” lack a respective server, the heat exchanger modular unit  40  adjacent those shelves may be removed from the mounting frame  22 . In a preferred embodiment, the empty location on the mounting frame may be replaced with a completely closed tray (no fans and no openings thereon which may be removably covered with cover  49 , for example, as explained above (or other closed panel mounted to frame  22  in the same or similar removable manner as the units  40 ) which acts to direct any warm air passing from the empty rack shelves to the next adjacent heat exchanger modular unit  40 . In this regard, it is noted that any number, including zero, of fans may be utilized as desired, regardless of the presence of servers in the server racks. With no fans present and/or operating in the cooling door, the passage of warm air through the cooling door will emanate from the electronic equipment fans or other auxiliary fans placed in the proximity of the server racks. It will thus be appreciated that the present system allows the cooling door  14  to be quickly and easily customized “on the fly” by the customer (with no special technician training needed) to accommodate intermittent changes in server numbers and locations within a rack  12  to thereby minimize energy usage and maximize operating efficiencies. 
         [0046]    In yet a further embodiment of the invention, variations in rack heights may be accommodated by incorporating a movable (e.g., freely slidable) shroud  70  located at the top of the door cover  16  which may be moved up or down on the door cover  16  as needed to accommodate different rack heights “H”. For example, today&#39;s server racks come in heights typically varying from 42 U to 45 U. The cooling door height may be made to align with the tallest server rack of 45 U. In this instance, shroud  70  would be moved all the way up so as to be out of the way and not cover any significant part of the door cover  16 . When using the same cooling door for a rack of a smaller height (e.g., 42 U), the shroud  70  may be moved downwardly to cover the top segment of the door cover  16  that extends above the shorter rack. In this way, air from the server room located above the shorter rack is blocked and not directed into the cooling door, thereby maintaining top operating efficiencies. 
         [0047]    As stated above, in a preferred embodiment, the heat exchangers are micro-channel heat exchangers and refrigerant (e.g., R134A) is the coolant which travels through supply and return lines  52 ,  54  respectively, the main headers  52   b,    54   b  for a server rack row  10  ( FIG. 1 ) of which may be positioned above each row  10  of server racks  12 . Individual rack refrigerant supply and return lines  52 ,  54  are directed along the hinge side  16   c  of the cooling doors ( FIGS. 5-5C ) and connect to a respective heat exchanger modular unit  40   a,    40   b,    40   c  via quick connect swivel couplings  72 . The refrigerant will flash to a gas at room temperature and there is thus no fear of damaging the servers should a leak occur in the supply or return lines  52 ,  54  as would be possible if the coolant used was water, for example, as is used in many prior art cooling systems. 
         [0048]    A further benefit of having removable mounting of the heat exchanger module units  40   a,    40   b  and  40   c  to a separate door mounting frame  22  is that the door cover  16 , which includes the door handle  20 , may be attached to the rack in either a right opening or left opening door orientation. The door cover  16  and mounting frame  22  (which have been previously connected together as explained above) may thus be first connected to a respective rack  12  in either a left opening or right opening manner by simply rotating the door 180° as necessary to achieve the desired orientation. Once the door cover  16  with mounting frame  22  is attached to the rack  14 , the desired number of heat exchanger modular units  40  are removably mounted to the mounting frame  22  as explained above. The ability to removably mount the heat exchanger modular units  40   a,    40   b,    40   c  to the mounting frame  22  is not dependent on which 180° orientation of the door cover and mounting frame is chosen. This is due to the configuration of the heat exchanger/mounting frame cooperative mounting components which, as stated above, are preferably in the form of a plurality of longitudinally spaced openings  24   a,    26   a  formed in each side frame member  24 ,  26  of the mounting frame  22  and key-hooks  60 , for example, extending from the heat exchanger modular unit  40 . The openings  24   a,    26   a  in the mounting frame  22  are preferably the same symmetrical configuration regardless of which 180° orientation is chosen for the door cover and mounting frame. Each heat exchanger modular unit  40   a,    40   b,    40   c  may thus be removably mounted to the mounting frame  22  by passing the key-hooks  60  through respective openings  24   a,    26   a  in the mounting frame side members  24 ,  26 . Once inserted and manually released, gravity secures and maintains the heat exchanger modular units  40   a,    40   b,    40   c  on the mounting frame  22  by virtue of the key-hook  60  or other like element frictionally engaging the respective opening. 
         [0049]    Further operating efficiencies may be realized by electronically controlling the fans to turn on, off and/or change speeds in response to the sensed heat load at any given time or time intervals using temperature or other suitable sensors. 
         [0050]    While this method and apparatus has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as described.