Patent Description:
Semi-modular assemblies allow for certain portions of the assembly to be modularized such that changing one component of the assembly will not necessarily require dismantling or moving another component of the assembly. However, current semi-modular assemblies are still floor to roof structures that prevent further modularization without adversely affecting the performance of the data center. For instance, such assemblies require a ceiling grid to act as an interface between the hot plenum and the lower aisle containment of the server room. As many data center sites do not have uniform roof structures and heights, in order to maintain a certain level of data center performance, semi-modular assemblies still require that assembly components be customized for the construction of each data center.

<CIT>discloses a data center air duct system for cooling IT equipment.

In accordance with an aspect of the disclosure, a data center system is provided according to claim <NUM> with further aspects defined in the dependent claims.

This technology is directed to a modularized assembly, such as for server halls of a data center, enabling certain components of the assembly to be engaged and disengaged from the assembly without affecting other components of the assembly, as desired. Moreover, these portions of the assembly can come together as a kit ready to be installed and allow for increased efficiency in the construction of new data centers.

<FIG> depicts assembly <NUM> having cooling frame <NUM>, distribution frame <NUM>, server racks <NUM>, and supports <NUM>. Server racks <NUM> are substantially rectangular however, in other examples, the server racks can have any other geometric shape, such as cylindrical, cuboid, spherical, or the like. Server racks <NUM> can house various electrical components for use in a data center, such as a number of computing servers, memory components, or the like. Server racks <NUM> can be configured to direct hot air generated from the electrical components toward a hot air corridor <NUM> along the Y-direction defined between the server racks. Hot air corridor <NUM> can be configured to receive the hot air from the electrical components housed in server racks <NUM>.

Supports <NUM> are secured at each end of assembly <NUM> to the floor through bottom end <NUM>. Cooling frame (or module) <NUM> is secured to a top end <NUM> of support <NUM> and houses a cooling unit <NUM> therein. Cooling unit <NUM> can be configured to receive the hot air rising from hot air corridor <NUM> and to expel a cool medium, such as cold air, from the faces of the cooling frame facing the Y-direction such that the cold air falls down onto server racks <NUM> to cool down the electrical components within the server racks. Support <NUM> are received within hot air corridor <NUM> to decrease the total width of assembly <NUM> along the Y-direction as well as to more efficiently concentrate the hot air to rise into cooling unit <NUM>.

Distribution frames (or modules) <NUM> are secured to opposing faces of the cooling frame <NUM> facing along the Y-direction and above server racks <NUM>. Distribution frames <NUM> can be placed above server racks <NUM> as the components of the server racks can require more maintenance than the accessories of the distribution frames. In this manner, server racks <NUM> is placed in a position that is more accessible than distribution frames <NUM>. Distribution frames <NUM> includes a number of accessories, such as bus plugs <NUM>, transfer switches <NUM>, cable trays <NUM>, bus ducts <NUM>, distribution units <NUM>, as further discussed below. The accessories can be facing along a Y-direction to enable distribution frame <NUM> to be more easily installed onto cooling frame <NUM>. The accessories will be described in more detail below.

Assembly <NUM> can be assembled from a kit of parts including cooling frame <NUM> with or without cooling unit <NUM> already installed to the cooling frame, distribution frame <NUM> with or without any of the accessories, server rack <NUM>, and struts <NUM>. In this manner, assembly <NUM> is modularized such that each component of the assembly can arrive in the kit ready for installation as well as being able to be removed and installed for maintenance without affecting other components of the assembly.

<FIG> depicts cooling frame <NUM> housing a cooling unit <NUM> therein. Cooling unit <NUM> can be any means of providing cool air such as a fan, cooling distribution unit, liquid cooler, or any other means of cooling hot air from hot air corridor <NUM>. Further, cooling unit <NUM> can be configured to receive hot air along a Z-direction from hot air corridor <NUM> and expel a cool medium (such as air) from one of faces of cooling frame <NUM>, such as the faces of the cooling frame facing along the Y-direction. Alternatively, the cool medium can be a cool liquid expelled along a pipe coupled to the cooling unit.

Cooling frame <NUM> comprises a number of main struts <NUM>, a number of orthogonal struts <NUM>, and a number of diagonal support struts <NUM>. Main struts <NUM> can define the shape of cooling frame <NUM> while orthogonal struts <NUM> and diagonal struts <NUM> can provide structural support to the cooling frame. As main struts <NUM> define a substantially rectangular frame cooling frame <NUM>, the main struts therefore define six faces of the cooling frame facing along one of an X-, Y-, or Z-direction and defining a number of openings. In another example, main struts <NUM> can define a different geometrical shape for cooling frame <NUM> with a corresponding number of faces. For instance, main struts <NUM> can define a pyramidal cooling frame <NUM> with four faces or any other shape.

Orthogonal struts <NUM> are connected along a length of main struts <NUM> and extend substantially along an X-, Y-, or Z-direction. Diagonal struts <NUM> extend from a corner defined between a pair of orthogonal struts <NUM> along a direction toward an opposite corner defined by an opposite pair of horizontal and vertical struts.

The number of intervening struts <NUM>, <NUM> provided for each face of cooling frame <NUM> can depend on the area of each face of the cooling frame; the larger the area of each face of the cooling frame, the greater number of intervening struts are required to provide sufficient support. For instance, the faces of cooling frame <NUM> facing the Y-direction has a larger area than the faces of the cooling frame facing the X- or Z-directions, while the area of the faces of the cooling frame facing the Z-direction is larger than the area of the cooling frame facing the X-direction. As such, the faces of cooling frame <NUM> facing the Y-direction each have seven orthogonal struts <NUM> and eight diagonal struts <NUM> while the faces of cooling frame <NUM> facing the Z-direction each have two orthogonal struts and six diagonal struts, and the face of cooling frame <NUM> facing the X-direction each have one orthogonal strut and four diagonal struts. In another example, there can be more or less intervening struts <NUM>, <NUM> on each face of cooling frame <NUM>, such as only three orthogonal struts <NUM> and four diagonal struts <NUM> on each face of the cooling frame facing the Y-direction.

Struts <NUM>, <NUM>, <NUM> may be substantially rectangular and hollow. In this manner, struts <NUM>, <NUM>, <NUM> can provide structural support to cooling frame <NUM> while minimizing the weight of the cooling frame. In another example, struts <NUM>, <NUM>, <NUM> can be cylindrical, triangular, or any other geometric shape. In yet another example, struts <NUM>, <NUM>, <NUM> are not hollow.

Plates <NUM> are substantially rectangular and are secured to bottom ends of main struts <NUM>. Plates <NUM> can be configured to engage with a top end <NUM> of supports <NUM> through fasteners, rivets, screws, or the like. Plate <NUM> enables cooling frame <NUM> to be modularized as the cooling frame can be disengaged from assembly <NUM> by disengaging plate <NUM> from support <NUM> without affecting other components of assembly <NUM>, such as distribution frames <NUM>, server racks <NUM>, or supports <NUM>.

Plates <NUM> are substantially rectangular and are secured to orthogonal struts <NUM> along a face of cooling frame <NUM> facing along the Z-direction. Plates <NUM> can secure cooling unit <NUM> to cooling frame <NUM> through fasteners, rivets, screws, or the like. In another example, plates <NUM>, <NUM> can have any geometrical shape, such as circular, triangular, or the like. Struts <NUM>, <NUM>, <NUM> and plates <NUM>, <NUM> can be secured to each through fasteners, rivets, welding, metal stitching, or any other means of securement.

<FIG> depict distribution frame <NUM> in a base, unassembled condition and an assembled condition. <FIG> depicts distribution frame <NUM> in a base condition, prior to having any accessories installed, such as bus plugs <NUM>, transfer switches <NUM>, cable trays <NUM>, bus ducts <NUM>, and distribution unit <NUM> while <FIG> depicts the distribution frame in an assembled condition including such accessories. In this manner, the accessories can be installed onto distribution frame <NUM> prior to shipment of assembly <NUM> so that the electrical distribution of the various accessories can be assembled and tested under a controlled environment prior to shipment to the prospective data center for assembly.

Distribution frame <NUM> has a substantially rectangular frame and a number of openings along each face of the frame as defined by main struts <NUM>. Orthogonal struts <NUM> can provide support to distribution frame <NUM>. Orthogonal struts <NUM> are connected along a length of main struts <NUM> and extend substantially along an X- or Z-direction. In another example, there may be diagonal struts extending from a corner defined between a pair of orthogonal struts <NUM> and/or main struts <NUM> along a direction toward an opposite corner defined by an opposite pair of orthogonal struts and/or main struts.

Struts <NUM>, <NUM> may be substantially rectangular and hollow. In this manner, struts <NUM>, <NUM> can provide structural support to distribution frame <NUM> while minimizing the weight of the cooling frame. In another example, struts <NUM>, <NUM> can be cylindrical, triangular, or any other geometric shape. In yet another example, struts <NUM>, <NUM> are not hollow.

Distribution frame <NUM> includes plate <NUM> extending from the distribution frame along the Y-direction. Plate <NUM> can be configured to engage with a face of cooling frame <NUM>, such as the faces of the cooling frame facing the Y-direction. As such, distribution frame <NUM> can be secured to cooling frame <NUM> through plate <NUM> being fastened, riveted, screwed, or the like. Plate <NUM> enables distribution frame <NUM> to be modularized as the distribution frame can be disengaged from assembly <NUM> by disengaging plate <NUM> from cooling frame <NUM> without affecting other components of assembly <NUM> such as the cooling frame, other distribution frames, server racks <NUM>, or supports <NUM>.

Transverse struts <NUM> extend along a Y-direction from main struts <NUM>, orthogonal struts <NUM>. Transverse struts <NUM> may be similar in structure to struts <NUM>, <NUM>. Arms <NUM> extends along a Y-direction from a base plate <NUM> secured to main struts <NUM> and orthogonal struts <NUM>. Base plate <NUM> can be secured to struts <NUM>, <NUM> through fasteners, rivets, welding, or the like. In another example, arms <NUM> and transverse struts <NUM> can additionally or alternatively extend along any direction, such as an X- or Z-direction. In a further example, there may be no transverse struts <NUM>. In other examples, there can be any number of arms <NUM> and the arms can have any amount of spacing apart from each other.

Arms <NUM> and transverse struts <NUM> can provide support for adjacent accessories. In other examples, the arrangement of arms <NUM> and transverse struts <NUM> can be changed to accommodate for the type and size of various accessories. For instance, turning to <FIG>, distribution frame <NUM> is depicted in an assembled condition including bus plugs <NUM>, transfer switches <NUM>, cable trays <NUM>, bus ducts <NUM>, and distribution unit <NUM>. Bus plugs <NUM> can provide power to various components of assembly <NUM>, such as server racks <NUM>. Transfer switch <NUM> can switch between different sets of bus pugs <NUM>. Cable trays <NUM> can house the cables that connect to various parts of assembly <NUM>, such as the cables connected to bus plugs <NUM>. Bus ducts <NUM> can transfer power generated to bus plugs <NUM>. Distribution units <NUM> can receive an end of a number of cords or cables such that the position of the cords or cables can be better maintained, and the cords or cables can be more easily accessible.

Each row of bus ducts <NUM> is supported by a corresponding row of arms <NUM>. For example, where assembly <NUM> includes two rows of bus ducts <NUM> vertically separated from each other, a first top row of bus ducts can be supported by a first top row of arms <NUM> and a second bottom row of bus ducts can be supported by a second bottom row of arms beneath the top row of arms along the Z-direction. This configuration efficiently uses the available space of the data center as the accessories less likely to be interacted with, such as bus ducts <NUM>, can be placed in a higher, less accessible area while accessories more likely to be interacted with, such as cable trays <NUM>, can be placed in a lower, more accessible area. Bus ducts <NUM> can be secured to its supporting arms <NUM> by one of fasteners, rivets, welding, or the like.

Each row of bus plugs <NUM> is secured to a corresponding row of bus ducts <NUM> through bus lips <NUM> extending along a Y-direction toward the bus ducts. In this manner, arms <NUM> can indirectly provide support to bus plugs <NUM> through bus ducts <NUM>. Bus lips <NUM> can provide direct engagement between bus plugs <NUM> and bus ducts <NUM> such that the bus ducts can provide power directly to the bus plugs to be passed along to other components of the data center and assembly <NUM>. Bus lips <NUM> can be secured to bus ducts <NUM> through fasteners, rivets, welding, or the like. Bus plugs <NUM> can be configured to provide electrical power to various electronic components of assembly <NUM>, such as server racks <NUM>. Bus ducts <NUM> can be made of a conductive metal such as copper, aluminum, or any other metal capable of conducting electricity from bus plugs <NUM>.

There are multiple rows of bus plugs <NUM> and bus ducts <NUM> to account for any potential loss in power. As a loss of power can have detrimental effects on the performance of a data center, multiple sets of bus plugs <NUM> and bus ducts <NUM> can enable a constant stream of power to the data center such as, when one set of bus plugs fails, another can start working in its place. Transfer switches <NUM> can allow for such a switch between one set of bus plugs <NUM> to another. For instance, where a top row of bus plugs <NUM> fails, transfer switch <NUM> can be activated to switch to a bottom row of bus plugs <NUM>. As such, transfers switches <NUM> are secured directly beneath bus plugs <NUM> to minimize lag time between switch bus plugs, as well as to reduce the length of cable between the transfer switches and bus plugs. Transfer switch <NUM> can be secured to distribution frame <NUM> through fasteners, rivets, welding, screws, or the like.

Distribution units <NUM> are secured to at least one of arms <NUM> or orthogonal struts <NUM> through fasteners, rivets, welding, screws, or the like. Distribution units <NUM> can receive an end of cord or cables of adjacent accessories, such as bus plugs <NUM> and transfer switch <NUM>. In this manner, the cord or cables of the adjacent accessories can be more easily accessible when certain operations are required to be performed on those accessories, such as replacements or the like.

Cable trays <NUM> are supported along lower rows of arms <NUM> and transverse struts <NUM>. Cable trays <NUM> can be secured to arms <NUM> and transverse struts <NUM> through fasteners, rivets, welding, or the like. Cable trays <NUM> can be configured to carry cables and other connecting accessories required to operate the accessories, such as for bus plugs <NUM>, transfer switches <NUM>, and distribution units <NUM>. As such, cable trays <NUM> are placed below the other accessories along the Z-direction to house the cables extending from their corresponding accessories.

However, in other examples, the accessories may have other arrangements. For instance, distribution units <NUM> can be secured to distribution frame <NUM> between a first row of bus plugs and a second row of bus plugs to provide optimal placement of the cords or cables for both rows of bus plugs <NUM>. In another example, there may be no distribution unit <NUM>.

<FIG> depicts support <NUM> having two columns <NUM> with top end <NUM> and bottom end <NUM>, and a connecting column <NUM>. Columns <NUM> are secured to each other through a connecting column <NUM> adjacent top end <NUM> of each column <NUM>. Columns <NUM>, <NUM> are monolithic structures that include two opposing faces, and an interior strut substantially orthogonal to each of the two opposing faces and extending along a central portion between each of the two opposing faces. In other examples, columns <NUM>, <NUM> may have any other shape, such as being rectangular, cylindrical, or any other geometric shape. Further, columns <NUM>, <NUM> may be hollow.

Bottom end <NUM> of columns <NUM> may include at least one hole <NUM> to receive a screw, fastener, or rivet to secure support <NUM> to the floor. Bottom end <NUM> of columns <NUM> may include any number of holes <NUM>, such as one, two, three, or any other number.

Support <NUM> includes plates <NUM> secured to top end <NUM> of each of columns <NUM>. Plates <NUM> are substantially rectangular but, in other examples, can have any other shape, such as circular, triangular, or the like. Plates <NUM> can be secured to columns <NUM> through fasteners, rivets, screws, or the like. The configuration of columns <NUM>, <NUM> can provide stability for loads placed on plates <NUM>, such as cooling frame <NUM> and distribution frames <NUM>. In other examples, plates <NUM> can have a number of holes (not shown) to receive a fastener, rivet, screw, or the like to engage a structure, such as cooling frame <NUM>, placed on top of the plates.

<FIG> depict another example assembly <NUM> including cooling frame <NUM> and cooling unit <NUM>, distribution frames <NUM>, and support <NUM> as described above. Assembly <NUM> includes extension frames (or modules) <NUM> secured between cooling frame <NUM> and one of distribution frame <NUM>. Extension frames <NUM> have a substantially rectangular shape defined by main struts <NUM> and include a number of intervening struts <NUM>. Intervening struts <NUM> can be a number of diagonal struts or orthogonal struts secured along a portion of main struts <NUM>. Intervening struts <NUM> can provide stability and support to extension frame <NUM>. Extension frame <NUM> can have a height extending along the Z-direction similar height to distribution frame <NUM>, however, in other examples, the extension frame may be taller or shorter. Extension frame <NUM> is secured between distribution frame <NUM> and cooling frame <NUM> such that a top end of the extension frame is aligned with a top end of the distribution frame and the cooling frame. In other examples, extension frame <NUM> may be secured between distribution frame <NUM> and cooling frame <NUM> along any portion of the distribution frame or cooling frame. Extension frame <NUM> can be secured to distribution frame <NUM> and cooling frame <NUM> through one of a fastener, rivet, screw, or the like.

Extension frame <NUM> can have a width extending along the Y-direction sufficient to provide a distance between distribution frame <NUM> and cooling frame <NUM> to define a space for objects to be received within assembly <NUM>, such as a building column (not shown) of the data center site. In this manner, where assembly <NUM> is planned to be assembled in a data center location having building columns that may interfere with the positioning of the assembly, extension frame <NUM> can be installed to provide a space for the building column without interfering with the performance of the assembly or affecting the efficiency of the data center to be constructed.

Assembly <NUM> also includes supports 610a,b having plates 611a,b along a top end and bottom end <NUM>. Supports 610a,b provide additional support to the distribution frame <NUM> that is secured to extension frames <NUM>. Supports 610a,b includes a plate 611a,b at a top end and a plate <NUM> at a bottom end. Plates 611a,b at the top end of supports <NUM> is secured to a bottom end of main strut <NUM> of distribution frame <NUM>. Through this engagement, plates 611a,b can provide load-bearing support to distribution frame <NUM>. Plate 611a,b is substantially rectangular however, in other examples, the plate may have any other shape such as circular, triangular, or any other geometry.

Plate 611a,b has a surface area sufficient to support at least one end of a distribution frame <NUM> however, in other examples, the plate can also have a surface area sufficient to support two ends of a distribution frame. For instance, plate 611b has a surface area is sufficiently large to support an end of a single distribution frame <NUM>. However, plate 611a has a surface area sufficiently large to support two adjacent distribution frames <NUM>, such as where there are two assemblies <NUM> adjacent each other. In other examples, plate 611a,b can have a surface area sufficiently large to support more than two ends of a distribution frame <NUM>. In further examples, supports 610a,b may be secured along any portion of distribution frame <NUM>, such as along a central portion of main strut <NUM> of the distribution frame. Further, there may be any number of supports 610a,b, such as one, three, four, or the like.

In other examples, there may be any number of extension frames <NUM> secured to distribution frame <NUM> and cooling frame <NUM>, such as four, five, six, or the like. In a yet further example, extension frames <NUM> may be secured along any face of cooling frame <NUM>, such as the faces of the cooling frame facing along the X-direction. In this manner, assembly <NUM> can be constructed to take into account various structures in a potential data center site. In another example, there may be no support <NUM> engaged with distribution frame <NUM>.

<FIG> depicts another example assembly <NUM> including cooling frame <NUM> housing cooling unit <NUM> and distribution frames <NUM> as described above. Extension frames <NUM> is similar to the extension frames described above in <FIG>, such as the width of the extension frames extending along the Y-direction, except the height of the extension frames of assembly <NUM> extend along an X-direction. Moreover, extension frames <NUM> are secured between cooling frame <NUM> and distribution frame <NUM> along a top end, central portion, and bottom end of the cooling frame and distribution frame. Assembly <NUM> includes diagonal struts <NUM> adjacent a top end and a bottom end of cooling frame <NUM> and distribution frame <NUM>. Diagonal struts <NUM> extends from cooling frame <NUM> along a direction in the Y-Z plane towards distribution frame <NUM>. Diagonal struts <NUM> can provide additional support to distribution frame <NUM>.

<FIG> depicts another example assembly <NUM> including cooling frame <NUM> and cooling unit <NUM>, distribution frames <NUM>, server racks <NUM>, and support <NUM> as described above. Assembly <NUM> further includes a number of pipes <NUM>. Pipes <NUM> are secured to a top portion of cooling frame <NUM> having a length extending along the X-direction and in line with the length of the cooling frame. Pipes <NUM> can be secured to cooling frame <NUM> through rivets, screws, or the like. Pipes <NUM> can be configured to communicate with cooling unit <NUM> to carry a liquid coolant to other portions of assembly <NUM> or the data center. In one example, pipes <NUM> may extend along any direction, including the Y- or Z-directions. In a further example, pipes <NUM> may have any length, including longer or shorter than cooling frame <NUM>. In a further example, there may be any number of pipes <NUM>, such as two, three, or the like. In other examples, pipes <NUM> can be secured along any portion of assembly <NUM>.

<FIG> depicts assembly structure <NUM> having a transport frame (or module) <NUM> secured between assemblies <NUM> as described above, except distribution frames are not installed on the assemblies. Transport frame <NUM> is secured between faces of cooling frame <NUM> of assembly <NUM> facing along an X-direction. Each end of transport frame <NUM> is secured to a support <NUM> through fasteners, rivets, screws, or the like. Transport frame <NUM> can carry certain accessories, such as cable trays, that may be used to replace other accessories of assembly structure <NUM>.

<FIG> depicts transport frame <NUM> having main struts <NUM> and intervening struts <NUM>. Main struts <NUM> defines the substantially rectangular shape of transport frame <NUM>. In other examples main struts <NUM> can define transport frame <NUM> to have any shape, such as cylindrical, pyramidal, or the like. Intervening struts <NUM> are secured along a portion of main struts <NUM> and orthogonally extend from those main struts. In other examples, intervening struts <NUM> can extend from main struts <NUM> at any angle, such as in a diagonal and nonorthogonal fashion from the main struts.

Transport frame <NUM> includes side struts <NUM> extending along a Z- or X-direction. Side struts <NUM> can provide additional support to transport frame <NUM>. Struts <NUM>, <NUM>, <NUM> can have a similar structure and shape as struts <NUM>, <NUM>, <NUM> as described above for cooling frame <NUM> in <FIG>. Further, transport frame <NUM> includes plates <NUM> secured to a bottom end of main struts <NUM> similar to plates <NUM> as described above for cooling frame <NUM> in <FIG>.

Arms 801a,b can have a similar structure and shape as arms <NUM> of distribution frame <NUM> in <FIG>. Arms 801a are free from any connecting structure however arms 801b includes cross connectors <NUM>. A first cross connector <NUM> can engage free ends of arms 801b along the X-direction. Elongate portion <NUM> extends along a Z-direction from ends of the first cross connector <NUM> engaged to arms 801b. Other cross connectors <NUM> that are not engaged to the arms 801b are secured in place along a length of elongate portions <NUM>. Cross connectors <NUM> can have a similar structure as arms 801a,b however, in other examples, the cross connectors can have a cylindrical shape, pyramidal shape, or the like. Arms 801a,b and cross connectors <NUM> can facilitate storage of accessories, such as cable trays <NUM>. Cable trays <NUM> are similar to cable trays <NUM> described above for distribution frames <NUM> in <FIG>.

Any portion of the assemblies or assembly constructions may be constructed in whole or in part, from one or more metals including, titanium and its alloys, stainless steel and its alloys, magnesium and its alloys, cobalt and its alloys, nickel and its alloys, silver, tantalum, or any other kinds of metals. Any portion of the assemblies may also be made from one or more polymers such as any one or combination of polyethylene (PE), high-density polyethylene (HDPE), polyvinyl chloride (PVC), silicone, cross-linked polymers, or any other polymers.

Any portion of the assemblies can be pre-fabricated from a monolithic workpiece, such as using a computer numerical control (CNC) machine, three-dimensional printing, or the like. For instance, cooling frame, distribution frame, server racks, supports, extension frame, and transport frame can be pre-fabricated from a monolithic workpiece.

Any portion of the assemblies or assembly constructions may be packaged together as a kit ready for installation. For instance, with reference to <FIG>, a kit for assembly <NUM> may include server racks <NUM>, supports <NUM>, distribution frames <NUM>, and cooling frame <NUM>. Cooling frame <NUM> may include cooling unit <NUM> already installed on the cooling frame, as depicted in <FIG>. However, in other examples, cooling frame <NUM> may be a part of the kit without cooling unit <NUM> installed.

Distribution frames <NUM> may be included in the kit in a base condition or assembled condition. For example, distribution frames <NUM> may be included in the kit in an assembled condition including at least one accessory installed on the distribution frame, such as bus plugs <NUM>, transfer switches <NUM>, bus ducts <NUM>, cable trays <NUM>, and distribution units <NUM> as depicted in <FIG>. In another example, distribution frame <NUM> can be included in a base condition without any accessories, as depicted in <FIG>.

The kit may further include a number of other components. With reference to <FIG>, the kit may include extension frames <NUM> and diagonal struts <NUM>. With reference to <FIG>, the kit may include pipes <NUM>. Pipes <NUM> may come installed on cooling frame <NUM>, or may be separate from the cooling frame and installed on-site. With reference to <FIG>, the kit may include transport frame <NUM>. Transport frame <NUM> may already have side struts <NUM>, cross connectors <NUM>, and elongate portions <NUM> installed, however, in other examples, such components are installed on-site. Further, cable trays <NUM> may already be stored within transport frame <NUM> in the kit, however, in other examples, the cable trays may be stored within the transport frame on-site.

The assemblies described above can be secured to the floor adjacent each other such that multiple assemblies formed together can form a server line. <FIG> depicts a server line <NUM> having a number of assemblies <NUM> as described above. Assemblies <NUM> are lined up adjacent each other along an X-direction to form server line <NUM>. In other examples, server line <NUM> can have more or less than three assemblies <NUM> forming a server line <NUM>, such as two, four, five, or the like. Moreover, a number of server lines can be secured adjacent each other to form a server array. <FIG> depicts server array <NUM> with a number of server lines <NUM> secured to the floor adjacent each other and extending along the X-direction. In other examples, server array <NUM> can have more or less than three server lines <NUM>, such as two, four, five, or the like.

With reference to <FIG> and <FIG>, a method of constructing assembly <NUM> will now be described. Although the below steps are described in a sequential order, it should be understood that the steps of the method may be performed in any order. A kit as described above may first be shipped out to a location for constructing a new data center. Once the kit has been received, each part of the kit may be used to construct assembly <NUM>. Certain parts of the kit may first be prepared prior to installation of assembly <NUM>. For instance, where cooling unit <NUM> was not installed within cooling frame <NUM> when the kit was shipped, the cooling unit can be installed to the cooling frame prior to assembling assembly <NUM>. Similarly, the accessories bus plugs <NUM>, transfer switches <NUM>, cable trays <NUM>, bus ducts <NUM>, and distribution units <NUM> may be installed on distribution frames <NUM>. In other examples, the accessories may be installed after distribution frame <NUM> has been installed on assembly <NUM>, as discussed below.

With reference to block <NUM>, a bottom end <NUM> of first support <NUM> may be installed to the floor. A second support <NUM> can then be installed a distance away from first support <NUM> to define a length of assembly <NUM> along the X-direction.

With reference to block <NUM>, a bottom end of cooling frame <NUM> is secured to supports <NUM> through plates <NUM> being fastened, screwed, riveted, or the like to the supports. Where cooling unit <NUM> is not already secured within cooling frame <NUM>, the cooling unit may be secured to the cooling frame through being fastened, screwed or riveted to plates <NUM>.

With reference to block <NUM>, a first distribution frame <NUM> is secured to a first face of cooling frame <NUM> that faces along the Y-direction through plates <NUM> through fasteners, rivets, screws, or the like. A second distribution frame <NUM> can then similarly be secured to a second face of cooling frame <NUM> that faces along the Y-direction opposite the first face of the cooling frame. Where distribution frames <NUM> do not already include accessories installed on the distribution frame, such accessories can be installed once the distribution frame is secured onto cooling frame <NUM>. For instance, bus ducts <NUM> may be secured to, and supported by, arms <NUM>. Bus plugs <NUM> may then be secured to bus ducts <NUM> by engaging bus lips <NUM> to the bus ducts such that the bus plugs face along the Y-direction. Transfer switches <NUM> and distribution units <NUM> may be secured to distribution frame <NUM> through fasteners, rivets, screws, or the like. Cable trays <NUM> may be secured onto, and supported by, arms <NUM>.

With specific reference to <FIG>, where the kit included extension frames <NUM>, diagonal struts <NUM>, and supports 610a,b, the extension frames may be installed to cooling frame <NUM> prior to distribution frames <NUM> being installed. For instance, extensions <NUM> may be secured to a face of cooling frame <NUM> facing along the Y-direction through fasteners, rivets, screws, or the like. Extension frames <NUM> may be secured to cooling frame <NUM> along main struts <NUM> such that a length of the extension frames extend along a Z- or X-direction while a width of the extension frame extends along a Y-direction. Diagonal struts <NUM> may additionally be installed along a portion of cooling frame <NUM>. Supports 610a,b may be secured to the floor along bottom end <NUM> in a position configured to support a distribution frame <NUM>. At least one distribution frame <NUM> can then be secured to an end of extensions <NUM> along main struts <NUM>. A bottom end of distribution frame <NUM> can be secured to a plate 611a,b of support <NUM>.

With specific reference to <FIG>, where the kit includes pipes <NUM>, the pipes may be secured to a top face of cooling frame <NUM> to extend long an X-direction. In other examples, pipes <NUM> may be secured to cooling frame <NUM> to extend along any direction, such as a Y-direction.

With specific reference to <FIG>, where transport frame <NUM> is included within the kit, a plate <NUM> of the transport frame may be secured to supports <NUM> such that a face of the transport frame facing along the X-direction may be secured adjacent to a face of cooling frame <NUM> facing along the X-direction. Where transport frame <NUM> does not already have side struts <NUM>, cross connectors <NUM>, and elongate portions <NUM> installed, such components may be installed prior to securing the transport frame to supports <NUM>. For instance, side struts <NUM> may be secured to a face of transport frame <NUM> facing along the Y-direction. Ends of cross connectors <NUM> can be secured to ends of arms 801b. Elongate portion <NUM> can be inserted within ends of cross connectors <NUM> to extend along a Z-direction and secure the other cross connectors. Cable trays <NUM> may be stored within transport frame <NUM> to be supported by at least one of arms 801a,b and cross connectors <NUM>.

With reference to block <NUM>, a first and second server racks <NUM> may be placed on either side of supports <NUM>, underneath distribution frames <NUM>, along the Y-direction to define hot air corridor <NUM>.

Once assembly <NUM> has been assembled, in operation, the hot air from the electrical components within the server racks <NUM> can be directed to hot air corridor <NUM> defined between the server racks. The hot air will rise through cooling frame <NUM> along the Z-direction and be received in cooling unit <NUM>. Cooling unit <NUM> can generate a cool medium, such as air or liquid, using processes known in the art. For instance, where the cool medium is cool air, the cool air can be expelled along the Y-direction through cooling frame <NUM>. The cool air will fall down along the Z-direction through distribution frame <NUM> and onto server racks <NUM> to cool the server racks. In another example, cooling unit <NUM> can generate cool liquid to be piped along assembly <NUM> to cool down the assembly, such as through pipes <NUM>.

With specific reference to <FIG>, multiple assemblies <NUM> can be positioned adjacent each other along an X-direction to form a server line <NUM>. Such server lines <NUM> can then be positioned adjacent each other along a Y-direction to form server array <NUM>.

According to implementations, a kit for forming a data center comprises a first rack, a second rack, a first support having a first end and a second end opposite the first end, the first support configured to be secured to the floor at the first end, a cooling frame having a cooling unit received therein, the cooling frame having a first face and a second face opposite the first face, the cooling frame configured to be secured to the second end of the first support, a first distribution frame having a first plurality of support arms extending therefrom, the first distribution frame configured to be coupled to the first face of the cooling frame, and a second distribution frame having a second plurality of support arms extending therefrom, the second distribution frame configured to be coupled to the second face of the cooling frame.

Modularization and standardization of data center components allows for greater efficiency in both construction and maintenance of data centers. Having a set of modular and standardized components can minimize the amount of time required to plan for data center construction and to actually construct the data center. Moreover, modularization enables such components to be easily replaced without affecting other components of the data center. In this manner, there can be decreased down time for data centers during maintenance. Moreover, maintenance costs can be decreased, such as when modular data center components need to be replaced, as less equipment is needed to replace these components since the component can be replaced without affecting other components.

However, current practices of constructing data centers are not fully modularized in the same manner as the assemblies of this disclosure. Modern data centers involve many floor-to-roof components, preventing full modularization without detrimentally affecting thermal zone management and server performance. During maintenance under current practices, to replace or repair a certain component of the data center, large portions of data centers unrelated to that component must be engaged and disengaged in order. Moreover, even where certain components of data centers under current practices are modularized, it can be difficult to arrange such components in a manner that allows for an efficient operation of a data center, given the confines of data center sites, without further customizing such components and negating the benefits of having a set of standardized, modular data center components.

The assemblies of this disclosure are an improvement on current practices of constructing data centers by further modularizing data center components. As the assemblies of this disclosure are not floor-to-roof structures, each component may be directed to a certain function such that each component can be easily replaced without inconveniencing other components of the data center. For instance, a distribution frame can be directed to housing bus plugs that provide power to the data center while a cooling frame can include a cooling unit directed to cooling the server racks. As such, the distribution frame is a modular component separate from the cooling frame, thus allowing for the distribution frame to be disengaged from the assembly without affecting the performance of the cooling frame.

Moreover, the increased modularity of the assemblies of this disclosure enable the assemblies to be constructed in a variety of potential data center layouts without affecting the performance of the data center, or taking into account the roof structure and height of each layout. Each assembly can be a discrete unit that is capable of optimally and efficiently housing and powering servers such that a formation of multiple assemblies can be quickly planned out and assembled over a wide variety of data center layouts with little to no changes to the standard structure of an assembly. As the construction of each assembly of the disclosure enables each assembly to maintain an efficient operation, there is less need to customize components of the assembly to conform to a given data center layout in order to achieve a desired efficiency. This decreased need for customization allows for a standardization in data center components that contribute to both decreased complexity in planning and decreased resources required to construct the data center.

Further, the modularized assembly allows for better quality and consistency in the construction of server assemblies. In current practices of constructing data centers, the efficiency of each assembly team at each construction site may vary depending on the experience and skill of each team. The modularized assembly of the disclosure allows for a consistent and stable assembly team that manufactures each component of the modularized assembly prior to shipping the kit to each construction site. In this manner, each component's quality can be ensured to be at a minimum standard prior to shipping them to the data center construction site. Moreover, having a consistent assembly team can assist in lowering labor costs as improvements in the efficiency of the assembly team in manufacturing each component of the modularized assembly kit leads to a uniform improvement in efficiency in all constructions of the modularized assembly rather than just an improvement in efficiency at a specific job site.

Claim 1:
A data center system (<NUM>) comprising:
a first rack (<NUM>) and a second rack (<NUM>) defining a hot air corridor (<NUM>) therebetween;
a first support (<NUM>) having a first end and a second end opposite the first end, the first end of the first support is configured to be secured to a floor within the hot air corridor;
a cooling frame (<NUM>) secured to the second end of the first support, the cooling frame having a first face and a second face opposite the first face;
a cooling unit (<NUM>) secured within the cooling frame, the cooling unit configured to receive hot air from the hot air corridor and expel a cool medium from the first face and the second face of the cooling frame down onto the first and second rack (<NUM>);
a plurality of pipes (<NUM>) secured to a top portion of the cooling frame (<NUM>), wherein the plurality of pipes (<NUM>) are configured to communicate with the cooling unit (<NUM>) to carry a liquid coolant to portions of the data center system;
a first distribution frame (<NUM>) coupled to the first face of the cooling frame; and
a second distribution frame (<NUM>) coupled to the second face of the cooling frame.