Patent Publication Number: US-10317151-B2

Title: Water collection system for indirect evaporative cooler

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 15/123,152 [now U.S. Pat. No. 9,970,719], filed Mar. 13, 2014, entitled WATER COLLECTION SYSTEM FOR INDIRECT EVAPORATIVE COOLER, which is a U.S. National Stage Application under 35 U.S.C. § 371 of International Application No. PCT/US2014/026565, filed Mar. 13, 2014, entitled WATER COLLECTION SYSTEM FOR INDIRECT EVAPORATIVE COOLER, each of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF DISCLOSURE 
     1. Field of Disclosure 
     The present disclosure relates generally to indirect evaporator cooler systems, and more particularly to a water collection system for an indirect evaporative cooler configured to spray water on a heat exchanger of the indirect evaporative cooler. 
     2. Discussion of Related Art 
     Indirect air evaporative cooling systems typically use outdoor air to indirectly cool data center air when the outside temperature is lower than the temperature set point of the IT inlet air, which can result in significant energy savings. Such systems use fans to blow cold outside air across an air-to-air heat exchanger, which in turn cools the hot data center air on the inside of the heat exchanger, thereby completely isolating the data center air from the outside air. This heat removal method normally uses an evaporative assist, in which the outside of the air-to-air heat exchanger is sprayed with water, which further lowers the temperature of the outside air and thus the hot data center air. Indirect air evaporative cooling systems can provide cooling capacities up to about 1,000 kilowatts (kW). Most units are roughly the size of a shipping container or larger. These systems mount either on a building roof or along a perimeter of the building. 
     Using fresh air directly to cool a data center is often viewed as the most efficient cooling approach. For data centers experiencing a wide range of temperature and humidity conditions, this cooling approach is often the most efficient. However, the majority of data center managers are risk-averse to higher temperatures and rapid changes in temperature and humidity. With rising densities and the adoption of containment practices, it is undesirable to allow IT equipment to run at higher temperatures, especially if a failure event occurs. When temperature and humidity thresholds are kept within industry-recommended limits, indirect air economizers actually provide greater efficiency than direct fresh air. 
     With modern indirect evaporative cooling systems, hot IT air is pulled into a cooling module, and one of two modes of economizer operation is used to eject the heat. Based on the load, the IT set point, and outdoor environmental conditions, the system automatically selects the most efficient mode of operation. The indirect air-to-air economization mode uses an air-to-air heat exchanger to transfer the heat energy from the hotter data center air to the colder outdoor air. When evaporative cooling is used, water is sprayed over the heat exchanger to reduce the surface temperature of the exchanger. By spraying water on the heat exchanger, the air temperature is reduced close to the wet bulb temperature of the outdoor air. This mode of operation allows the data center to continue to benefit from economizer mode operation, even when the air-to-air heat exchanger alone is unable to reject the data center heat load. 
     In one known system, a water collection system of the indirect evaporative cooler includes a matrix of troughs having four or more rows and twenty or more columns is provided for collecting water that is sprayed within an indirect evaporative cooler on the heat exchangers. Each trough is installed individually and sealed, thereby creating a very high piece count and high labor burden to manage complexity. Additionally, since the matrix of troughs is typically a welded assembly that requires a higher skill set for assembly. 
     SUMMARY OF DISCLOSURE 
     One aspect of the present disclosure is directed to a water collection system for an indirect evaporative cooler. In one embodiment, the water collection system comprises a housing having an open bottom, a front wall, a back wall, and two end walls, which together define an interior region of the housing, a plurality of tube assemblies each extending through one of the front wall and the back wall of the housing and disposed within the interior region of the housing, and a plurality of panel assemblies disposed within the interior region of the housing above the plurality of tube assemblies, each panel assembly being associated with a respective tube assembly to channel fluid to the tube assembly. 
     Embodiments of the water collection system further may include providing each tube assembly with an extrusion body having one end sealed in such a way as to prevent the tube assembly from passing completely through the back wall of the housing. Each panel assembly may include two molded panels adhered to on opposite sides of a flat center panel. A series of holes and posts may be arranged on each molded panel such that the molded are self locating with respect to the center panel. Each molded panel may be molded with a pattern of funnels such that the funnels are alternately staggered vertically. Each funnel may include an inlet provided at a top of the funnel and an outlet provided at a bottom of the outlet. The inlet may be rectangular and has an area greater than an area of the outlet. The outlets of the funnels may be aligned to interface with a respective drain tube assembly. Each molded panel may be assembled to each side of the center panel, with the rectangular inlet of a long funnel being opposite to the rectangular inlet of a short funnel along a length of the panel. When the panel assemblies are installed into housing, the rectangular inlets of the funnels may be staggered vertically and horizontally in a checkerboard pattern. Two corners of the rectangular opening of each funnel may be chamfered such that when the panel assemblies are disposed in the housing, the chamfered corners align to provide an overlap of funnel opening areas. The housing may include a row of openings formed in the front wall and a row of openings formed in the rear wall to locate the plurality of tube assemblies. The housing further may include a front flashing member and a back flashing member to divert water toward one of the plurality of panel assemblies. Each flashing member may include a plurality of notches formed therein to allow the panel assemblies to intersect the flashing member to locate upper corners of the panel assemblies and to secure the panel assemblies from lateral or vertical movement. 
     Another aspect of the disclosure is directed to a method of collecting and distributing water within an indirect evaporative cooler configured to spray water on a heat exchanger. In one embodiment, the method comprises: channeling water with a plurality of panel assemblies disposed within an interior of a housing; depositing water from the panel assemblies to a plurality of tube assemblies positioned below the panel assemblies within the housing; and collecting water from the plurality of tube assemblies to be redistributed within the indirect evaporative cooler. 
     Embodiments of the method further may include providing each panel assembly with two molded panels adhered to on opposite sides of a flat center panel, each molded panel including a pattern of funnels, the method further comprising staggering the funnels vertically with respect to one another. The method further may include aligning outlets of the funnels to interface with a respective drain tube assembly. The method further may include assembling the two molded panels to respective sides of the center panel, with a rectangular inlet of a long funnel being opposite to a rectangular inlet of a short funnel along a length of the panel. The method further may include installing the panel assemblies into housing, the rectangular inlets of the funnels being staggered vertically and horizontally in a checkerboard pattern. The method further may include locating the plurality of tube assemblies within a row of openings formed in the front wall and a row of openings formed in the rear wall. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings: 
         FIG. 1  is a front perspective view of a water collection system of an embodiment of the present disclosure; 
         FIG. 2  is a back perspective view of the water collection system; 
         FIG. 3  is a top plan view of the water collection system; 
         FIG. 4  is an enlarged view of a portion of the water collection system shown in  FIG. 3 ; 
         FIG. 5  is an enlarged view of another portion of the water collection system shown in  FIG. 3 ; 
         FIGS. 6-8  are perspective views showing the assembly of component parts of the water collection system; 
         FIG. 9  is a perspective view of a funnel panel assembly of the water collection system; 
         FIG. 10  is a top plan view of the funnel panel assembly; 
         FIG. 11  is an end view of the funnel panel assembly; 
         FIG. 12  is an exploded perspective view of the funnel panel assembly; 
         FIG. 13  is a perspective view of a tube assembly of the water collection system; 
         FIG. 14  is a top plan view of the tube assembly; and 
         FIG. 15  is a perspective view of an indirect evaporative cooler having a portion of a housing removed with the water collection system. 
     
    
    
     DETAILED DESCRIPTION 
     This disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The principles set forth in this disclosure are capable of being provided in other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
     Many alternative cooling approaches have been developed and adopted over the last few years in an effort provide efficient heat removal from data centers. One such method that has gained recent favor is indirect evaporative cooling. This method minimizes/eliminates the need for energy intensive mechanical refrigeration. One challenge of indirect evaporative cooling is fabrication of the evaporative cooling cell and its associated water collection system. Current state of the art uses a high number of piece parts and significant assembly labor. 
     In one embodiment of the present disclosure, indirect evaporative cooling cells may include a plurality of thermally adjacent airflow channels. These channels are combined in parallel in such a manner as to provide two airflow paths. One path is provided for the conveyance of fluid to be cooled, e.g., heated air from the data center IT load. The other path is provided for the conveyance of the cooling fluid, i.e., ambient outdoor air enhanced by evaporation of flowing water over channel surface. Typically, water evaporation rate is only a fraction of the total water flow rate over the channel surface. This makes it necessary to collect water not evaporated for reuse as opposed to a less favorable once through design. A water collection system must impose minimal airflow resistance of the cooling fluid, i.e., ambient outdoor air, while offering near one hundred percent effective recovery of water that has not evaporated. 
     The water collection system of embodiments of the present disclosure reduces the piece part count by two-thirds, while reducing weight by twenty-five percent as compared to current state of the art water collectors having an array of individual troughs arranged in multiple rows of laterally offset columns. The improvements of the system of the present disclosure are the result of an arrangement of rectangular topped funnels disposed in a checkerboard pattern in two planes vertically offset from one another allowing easy passage of airflow but covering the entire the cross sectional area perpendicular to the flowing water. 
     Referring now to the drawings, and more particularly to  FIGS. 1 and 2 , a water collection system of embodiments of the present disclosure is generally indicated at  10 . The water collection system  10  is configured to be located within an indirect evaporative cooler or similar cooling unit. Specifically, the water collection system is configured to collect water that is sprayed by a spray assembly onto a heat exchanger located above the water collection system within the indirect evaporative cooler. The water collection system also may be provided to collect and manage rain that drops from the heat exchanger during operation. As shown, the water collection system  10  includes a housing, generally indicated at  12 , that supports the components of the water collection system. In the shown embodiment, the housing  12  includes an open bottom  14 , a front wall  16 , a back wall  18 , and two end walls  20 ,  22 , which together define an interior region of the housing that supports the components of the water collection system  10 . It should be understood that the housing  12  may be sized and shaped as required to suit the form factor of the particular cooler in which the water collection system  10  is installed. In one embodiment, the housing  12  is fabricated by riveting or welding panels of steel. However, any suitable materials may be utilized. 
     The water collection system  10  further includes a several tube assemblies, each generally indicated at  24 , which extend through the back wall  18  of the housing  12  and are disposed within the interior region of the housing. The water collection system further includes several of panel assemblies, each generally indicated at  26 , which are disposed within the interior region of the housing  12  above the tube assemblies  24 . As shown, each panel assembly  26  is associated with a respective tube assembly  24  and positioned directly above its respective tube assembly. Moreover, as shown, the panel assemblies  26  extend crosswise with respect to a length of the housing  12 . However, the panel assemblies  26  may be configured to extend lengthwise with respect to the length of the housing  12 . 
     Referring to  FIG. 3 , each panel assembly  26  includes a centerline  28  that is disposed directly above its respective tube assembly  24  so that the panel assembly extends along an axis that is disposed directly above and parallel to an axis of the tube assembly. In the shown embodiment, there are twenty-three tube assemblies  24  and twenty-three panel assemblies  26 ; however, any number of tube and panel assemblies may be provided depending on the size of the housing  12  or the sizes of the tube assemblies and panel assemblies of the water collection system  10 . 
     The housing  12  of the water collection system  10  further includes a front flashing member  30  and a back flashing member  32  to divert water toward one of the plurality of panel assemblies  26  disposed in the housing  12 . As shown, the front flashing member  30  is secured to the front wall  16  along a top edge of the front wall. Similarly, the back flashing member  32  is secured to the back wall  18  along a top edge of the back wall. Each flashing member  30 ,  32  includes respective notches  34 ,  36  formed in the flashing member to allow respective panel assemblies  26  to intersect the flashing member to more securely position the panel assemblies within the housing  12 . The notches  34 ,  36  are provided to locate upper corners of the panel assemblies  26  and to secure the panel assemblies to prevent lateral or vertical movement. The flashing members  30 ,  32  can be assembled to the front and back walls  16 ,  18 , respectively of the housing  12  with rivets, screws and/or by welding.  FIGS. 4 and 5  illustrate the manner in which the flashing members  30 ,  32  can be secured to the housing  12  as well as the notches  34 ,  36  provided in the respective flashing members. As shown, the flashing members  30 ,  32  are secured to their respective front and back walls  16 ,  18  by screws. 
     Referring to  FIGS. 6-8 , the manner in which the water collection system  10  is assembled is illustrated sequentially in these drawings.  FIG. 6  illustrates the tube assemblies  24  prior to their insertion into a row of openings, each indicated at  38 , formed in the front wall  16 , and into similar row of openings, each indicated at  40 , formed in the back wall  18  of the housing  12 . The openings  38  of the front wall  16  and the openings of the back wall  18  are aligned with each other to position the tube assemblies  24  within the housing  12  at a bottom of the interior of the housing. As shown, each tube assembly  24  is received within a respective opening  38  of the front wall  16  and a respective opening of the back wall  18  so that an end of the tube assembly is flush with the front wall and an opposite end of the tube assembly extends through the back wall. As will be shown and described in greater detail below, each tube assembly  24  includes an extrusion body having one end sealed in such a way as to prevent fluid from flowing out of the end of the extrusion body. The other end of the extrusion body is configured to drain in a suitable trough or other collection device to direct the fluid back to the spray assembly of the evaporative cooler. The construction of the tube assembly  24  will be described in greater detail below with reference to  FIGS. 13 and 14 . 
       FIG. 7  illustrates the insertion of the panel assemblies  26  of the water collection system  10  into the interior of the housing  12  above the tube assemblies  24 . As shown, the panel assemblies  26  are positioned above their respective tube assemblies  24  and held in place by the front wall  16 , back wall  18  and end walls  20 ,  22  of the housing  12 . In other embodiments, the panel assemblies  26  can be held in place with suitable fasteners to the respective walls of the housing  12 . 
       FIG. 8  illustrates a front panel  44  attached to the front of the housing  12  to create the front wall  16  with suitable fasteners, such as screw fasteners. The front panel  44  creates a neat, clean appearance, and covers the sealed ends of the tube assemblies  24 . As mentioned above, the flashing members  30 ,  32  are also secured to the housing  12  by suitable fasteners, such as screw fasteners. The ends of the panel assemblies are held in place by the notches  34 ,  36  formed in the front and back flashing members  30 ,  32 , respectively. 
     Referring to  FIGS. 9-11 , the assembled panel assembly  26  will be shown and described. Each panel assembly  26  includes an elongate, planar body  46  having a plurality of funnels  48 ,  50  positioned on both sides of the planar body. As shown, the funnels  48 ,  50  are configured in a pattern such that the funnels are alternately staggered vertically along a length of the planar body  46 . Specifically, the funnels  48 ,  50  are formed along the sides of the planar body  46  such that “long” funnels  48  and “short” funnels  50  alternate along the length of the side of the planar body. Each long funnel  48  includes an inlet  52  provided at a top of the funnel and an outlet  54  provided at a bottom of the funnel. Similarly, each short funnel  50  includes an inlet  56  provided at a top of the funnel and an outlet  58  provided at a bottom of the funnel. In one embodiment, each inlet  52 ,  56  is rectangular in construction and has an area greater than an area of its respective outlet  54 ,  58 . The outlets  54 ,  58  of the funnels  48 ,  50 , respectively, are aligned to interface with a respective drain tube assembly  24 . 
     Referring to  FIG. 12 , the planar body  46  and the funnels  48 ,  50  of each panel assembly  26  is fabricated from two molded panels, each indicated at  60 , adhered to on opposite sides of a flat center panel  62 . As shown, each molded panel  60  includes the funnels  48 ,  50  formed thereon, a series of posts, each indicated at  64 , which project from a side of the molded panel opposite the funnels, and a series of openings, each indicated at  66 , which are formed in the molded panel and aligned to receive the posts from the other molded panel therein. The posts  64  are formed on one end of the side of the molded panel  60  and the openings  66  are formed on the other end of the side of the panel. The arrangement is such that the molded panel  60  is reversible so that the molded panels can embody both sides of the planar body  46 . In one embodiment, the panels  60 ,  62  are assembled with a suitable adhesive or epoxy material. 
     The center panel includes a series of openings  68  formed therein, which are located to receive the posts  64  from the molded panels  60  therein. The arrangement is such that the molded panels  60  are self locating with respect to the center panel  62 . The two molded panels  60  are assembled to the sides the center panel  62 , with the rectangular inlet  52  of a long funnel  48  being opposite to the rectangular inlet  56  of a short funnel  50  along a length of the panel assembly  26 . The panel assemblies  26  are installed into housing  12 , with the rectangular inlets  52 ,  56  of the funnels  48 ,  50 , respectively, being staggered vertically and horizontally in a checkerboard pattern. In a certain embodiment, for each rectangular inlet  52 ,  56 , two corners of the rectangular inlets are chamfered such that when the panel assemblies  25  are disposed in the housing, the chamfered corners are aligned to provide an overlap of funnel opening areas. The molded panels  60  can be formed through an injection mold process from any suitable synthetic material. The center panel  62  can be molded, but also fabricated from a flat sheet with the holes formed therein punched or drilled. 
       FIGS. 13 and 14  illustrate the manner in which the tube assembly  24  of the water collection system  10  is assembled. As shown, the tube assembly  24  includes a body  70  having a top wall  72  with a plurality of openings, each indicated at  74 , formed along a length of the body. The openings  74  are positioned to correspond to the locations of the outlets  54 ,  58  of the funnels  48 ,  50  of the panel assembly  26  disposed above the tube assembly  24 . The arrangement is such that the funnel outlets  54 ,  58  are aligned with the openings  74  to receive water that is deposited within the inlets  52 ,  56  of the funnels  48 ,  50 , respectively, of the water collection system  10 . There are also smaller slots formed on either side of each opening  74 , which allow water that travels down the panel walls to enter the tube assembly. Each tube assembly  24  includes a rectangular end cap  76  to close one end of the body  70  of the tube assembly. The body  70  can be extruded from synthetic or other suitable material, while the end cap  76  can be formed through an injection mold process from synthetic material. In one embodiment, the end cap  76  is secured to the body  70  by a suitable adhesive or epoxy material. 
     Referring to  FIG. 15 , in one embodiment, the water collection system  10  is provided within an indirect evaporative cooler, generally indicated at  80 . One or more of these cooling modules may be arranged together to form a large cooling system. As shown, the indirect evaporative cooler  80  includes a housing, generally indicated at  82 , which in the shown embodiment is a box-like structure having an internal frame  84  and removable panels, each indicated  86 , which are used to enclose the interior of the housing. The indirect evaporative cooler  80  further includes a heat exchanger  88  supported within the interior of the housing  82  and a spray assembly  90  disposed above the heat exchanger and configured to spray water over the heat exchanger. The water collection system  10  is positioned below the heat exchanger  88  and provided to collect and recycle the water that is sprayed over the heat exchanger. As shown, all of the tube assemblies  24  protrude out from the back wall  18  of the housing  12  and empty into a central trough configured to collect the water for the cooling system. During operation, water is sprayed on the heat exchanger  88  by the spray assembly  90  to provide further cooling to the heat exchanger. The water that is sprayed on the heat exchanger  88  drips into the trough of the water collection system  10 , which is configured to cool the heated water more efficiently prior to being re-circulated or redistributed back the spray assembly  90 . The water collection system  10  is designed to sufficiently cover the entire surface area of the heat exchanger  88  so that all of the water sprayed on the heat exchanger is collected. A large fan is positioned below the water collection system  10  to direct the outside air through the water collection system, through the heat exchanger  88 , and through the top of the indirect evaporative cooler  80 . 
     As shown and described, the water collection system of embodiments of the present disclosure reduces the number and complexity of parts used in the system, improves water capture performance, includes fewer simpler drain points, lowers airflow pressure, and avoids excessive welding. 
     As shown, the checkerboard pattern of the funnels creates a continuous surface across the plane. However, by vertically offsetting the funnels, the surface of the water collection system provides continuous coverage of cross sectional area along a top surface of the system. 
     In one embodiment, the water collector assembly includes a welded sheet metal housing, with a row of openings in the front and rear walls that locate a series of drain tubes. The welded housing also incorporates flashing to divert water toward the first funnel panels located on each side. The flashing can be assembled to the housing with rivets, screws and/or welding. Each drain tube is an extrusion with one end capped off (sealed) in such a way as to prevent the tube from passing completely through the housing front wall. A single funnel panel assembly is then placed into the housing onto each drain tube. The funnel panel assemblies includes a molded panel (a single part) adhered to both sides of a flat center panel. There are a series of holes and posts arranged on the funnel panel such that the funnel panels are self locating to the center panel, which incorporates a hole pattern that accepts the posts from each funnel panel. Ideally, the panel assembly is assembled with an adhesive instead of fasteners for ease of manufacturing. 
     The funnel panels are molded with the a pattern of funnels such that the funnels are alternately staggered vertically, or such that the rectangular openings of the funnels are alternately staggered vertically, but that the funnel outlets are all aligned to interface with a single drain tube. When one funnel panel is assembled to each side the center panel, the rectangular funnel opening of the “long” funnel will be opposite of the rectangular opening of the “short” funnel in every location along the panel. Thus, when the funnel panels are installed into the water collector housing, all of the funnel openings are staggered vertically and horizontally, as in a three-dimensional “checkerboard” pattern. Additionally, each of the two corners of the rectangular openings of the funnels are chamfered such that when the panels are assembled into the water collector, the chamfered corners align to provide an overlap of the funnel opening areas when viewing from above. 
     The front and rear flashing includes a notch for allowing each funnel panel assembly to intersect the flashing, thereby locating the upper corners of the panels and securing the panels from lateral or vertical movement. The front and rear flashing can be assembled to the housing with rivets and/or screws. 
     A front panel is assembled to the front of the housing with screws and/or rivets to secure the drain tubes from sliding back out of the housing. Gaskets are then applied on some surfaces to seal those areas of the water collector inside the module. 
     In one embodiment, the offset between planes creating an air passage in an upward direction to provide cooling air source for the evaporative cooling. The funnel array(s) providing gravity water drain of collected water into common drain header. 
     Having thus described several aspects of at least one embodiment of this disclosure, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the disclosure. Accordingly, the foregoing description and drawings are by way of example only.