Patent ID: 12250794

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

In illustrative embodiments, three or more modules of a data center are oriented and configured to form an interior region for efficiently managing heat exhaust from the modules. To that end, each module has a housing forming an interior and, to regulate air flow, an air inlet and corresponding air outlet. Each module also has a plurality of interior processing devices (e.g., servers, computers, etc.) undesirably generating heat. In various embodiments, the air outlets direct hot exhaust air of each module into the interior region. That hot exhaust air preferably interacts with the hot exhaust air from other modules to more effectively remove heat from the module interior. Details of various embodiments are discussed below.

FIG.1schematically shows a data center10configured in accordance with illustrative embodiments of the invention. The data center10has a plurality of modules12arranged in a prescribed manner (discussed below) within a larger environment, and an energy source14to provide power to the modules12, their internal electronic components (e.g., servers), and other data center components. In preferred embodiments, the energy source14is a renewable source, such as a wind energy farm (shown), solar farm, hydroelectric plant, etc.

In addition or alternatively, other embodiments may connect the data center10to a municipal or other conventional electric grid. This connection can be so-called “behind-the-meter” and/or “in-front-of-the-meter.” For example, such embodiments may use electricity from the conventional electric grid at times when utility electricity costs are lower, and then use renewable power when utility electricity costs are higher. In fact, even when using the conventional grid, the renewable energy source can generate and store energy in batteries or other means for future use (e.g., when the conventional electric grid costs are high), and/or sell excess renewably produced energy back to the conventional electric grid. Those skilled in the art should appreciate that the data center10can utilize a variety of other renewable energy and/or non-renewable energy sources and as such, those discussed in this description are for illustrative purposes only.

The data center10also has a control system16that, among other things, stores and manages the supply of electricity generated by the energy source14. To that end, the control system16supplies electricity to the above noted plurality of modules12via the noted energy source(s)14. This control system16may be pre-programmed to automatically select when and which energy source to use (e.g., the grid or local renewable and/or a microgrid), amounts, etc. In addition, the control system16may have user interfaces to facilitate manual grid control, as well as control of various control functions for managing the modules12and their systems.

In various embodiments, some or all of the modules12are permanently built in the environment. For example, each module12may be constructed with conventional building techniques and products that make moving the module12substantially permanent (i.e., analogous to a conventional house or office building). For example, each module12may be placed on a cement pad or foundation and secured in a substantially permanent manner to the ground. Indeed, there are cumbersome and extraordinary ways to move a permanent structure, such as a house, and the module design in such embodiments may be subject to moving such ways.

In other embodiments, however, the modules12are secured to the environment in a manner where they may be more readily moved, analogous to a trailer or some mobile homes. Specifically, they may be sized and placed in the environment with equipment that makes module movement more available. For example, a given module12may be placed on a prepared portion of the ground at the desired location in the environment and nominally secured with stakes, fasteners, or other techniques. To move a module12(e.g., to fine tune their positions for optimal position relative to the prevailing wind), workers or others may simply remove any ground (removably) coupling equipment and move the module12to the desired new location.

To protect interior components (e.g., servers, computers, routers, etc.) from the environment, each module12has a housing18forming a thermally controlled interior. The module housing18of various embodiments may be implemented as a rectangular metal container, but may have other form factors and/or be formed from wood, plastic, concrete and other structural materials, or a combination of materials. Preferably, as noted below, the housings18have a sloped roof specially configured to manage airflow external, but proximate to, the module12. The housing18thus is a substantially enclosed structure that shelters its interior components from the environment. In various embodiments, such as some of those noted above, the housing18is structured so that the module12is portable and thus, it can be transported to different locations.

To provide its core function, the interior of the housing18contains a plurality of processing devices. In various embodiments, among other things, the processing devices include computers, servers, networking equipment (e.g., switches and routers), as well as various information security elements, such as physical security devices and firewalls. Those skilled in the art should understand that these components are illustrative and there is a variety of hardware, software, and combinations of hardware and software that can establish the functional components of a processing device and related accessories. The processing devices contained within the modules12perform any of a variety of common functions to support applications, such as blockchain computing, blockchain or bitcoin mining, web services, video or other multi-media transmission, storage, and data management.

As known by those in the art, the plurality of devices within each module12generates substantial amounts of heat during use. Environmental factors, such as high outdoor temperatures or sun exposure, also may increase the temperature within the modules12. Accordingly, each module12has a convective cooling system that directs air flow from an air inlet20A (aka “air intake”) on one side of the module12to an air exhaust or air outlet20B (aka “exhaust outlet”) on the opposite side. As shown inFIG.1(as well asFIG.3A, discussed below in greater detail), the modules12preferably are arranged so that the air exhaust/outlet side of the three or more modules12faces a common area; namely, an open, interior region22formed by the three or more modules12.FIG.1, for example, shows six sets of four modules12(referred to below as “module sets”) that each form this interior region22. Air outlets20B of each of the four modules12of each module set are directed toward the interior region22. Preferably, the exhaust air of the four modules12interact and are urged upwardly from the modules12.

In illustrative embodiments, each module12has a plurality of air movers24(e.g., one or more air movers24at or near the air inlet20A, and one or more air movers at or near the air outlet20B) that generate and control air flow within its interior. The air movers24can be passive or active devices and can include, among other things, fans, blowers, or turbines. Efficient regulation of internal module temperature mitigates heat-related damage and extends the useful life of the processing devices and, effectively the data center10itself.FIG.2schematically shows a diagram of the air flow of an exemplary single module12. Flowing from right to left from the perspective of that figure, relatively cooler air enters the air inlet side of the module12. The plurality of air movers24(schematically shown) within the modules12direct this cooler air through and/or around the processing devices. As it interacts with the devices within the module12, the inlet air gathers heat from the components, effectively convectively cooling the components and housing interior. The air movers24then direct the heated air (i.e., heated by thermal convection as the inlet air traverses toward the air outlet20B) to the air exhaust side of the housing18, where the air is expelled into the internal region22.

During use, however, the inventors discovered that hot air from the air outlet20B undesirably may recirculate back, over the top of the housing18, and back into the air inlet(s)20A. This recirculation consequently can substantially inhibit the cooling benefits, potentially damaging the internal components. To mitigate this problem, however, the housing roof26preferably is oriented in a non-horizontal configuration. In this example, the roof26of the housing18is sloped or angled relative to the horizontal (i.e., the horizontal roughly being the ground upon which the module12is mounted). Setting the angle too shallow can let too much of the hot air recirculate, however, while setting the angle too steep can adversely impact overall airflow in other ways. After testing, the inventors discovered that roof angles of between and including about 5-20 degrees should provide satisfactory results. More precisely, roof angles of between and including about 10-15 degrees are expected to provide satisfactory results.

The roof26in this embodiment may be considered to have an interior edge28on the same side as the air outlet20B, and an exterior edge30on the same side as the air inlet20A. The interior edge28therefore may be adjacent to or extend into the interior region22. As such, the distance from the exterior edge30to the interior region22is greater than the distance from the interior edge28to the interior region22. As shown inFIG.2, the interior edge28has a lower altitude (i.e., the distance in this case from the housing base to the interior edge28) than that of the exterior edge30. In other words, the distance from the base of the housing18to the interior edge28is smaller than the distance from the base of the housing18to the exterior edge30. These edges28and30also can form overhangs, as shown inFIG.2, or end at the wall forming the respective inlet and outlet sides of the housings18and thus, not form overhangs.

While the sloped roof26may suffice in some environments, the module12also may position and orient that air inlet20A and air outlet20B relative to each other in a manner that further mitigates air recirculation. Among other things, the air outlet20B may be more concentrated, urging outlet air into the environment at a higher flow rate. In fact, these flow rates can be coordinated with other modules12in the same module set31(i.e., the three or more modules12forming a single interior region22) to optimize thermal release and air flow. As such, the surface area permitting of the air inlet20A (i.e., the open spaces permitting air to enter a housing18/module12) may be greater than that for the surface area forcing air out of the housing18/module12. In addition, the air inlet20A may start at a higher altitude than those of the air outlet20B. Specifically, in the embodiment ofFIG.2, the air inlet20A is considered to have top and bottom air inlet edges32A and32B. In a corresponding manner, the air outlet20B is considered to have top and bottom air outlet edges34A and34B. To mitigate undesired air recirculation, the inventors recognized that the altitude of the top air inlet edge32A preferably is higher or greater than the altitude of the top air outlet edge34A. In addition or alternatively, the altitude of the bottom air inlet edge32B preferably is lower or less than the altitude of the bottom air outlet edge34B.

Those skilled in the art can select the appropriate shape, area, configuration, and size of the air inlet20A and air outlet20B consistent with the teachings of this description. For example, the air inlet20A and air outlet20B each can be formed from a plurality of openings of prescribed size and shape. That size and shape can be a function of the desired air flow and pressures within the module housing18. For example, the air inlet20A can be formed from a plurality of horizontally oriented, rectangular openings. Preferred embodiments form the air outlets20B in a position that minimizes the amount of air that changes direction between the air inlet20A and the air outlet20B. To that end, in a single module12, the air inlet20A preferably is in a region directly across from its corresponding air outlet20B. For example, in a given module12, the air inlet20A may be defined on a wall forming the interior region22of the three or more modules12, while the air outlet20B may be on a wall opposite the wall containing the air inlet20A (e.g., the wall farthest from the wall forming the air inlet20A).

Each module12also may have a plurality of buffers or scaffolds (“buffer36”, e.g., on the roof26of the module12and/or integrated into the air inlet20A) to further mitigate the amount of air that recirculates through the module12from the air outlet20B. The buffer/scaffolds36of the embodiment ofFIG.2may be implemented as hoods that block air coming downwardly directly into the air inlet openings in the side of the housing18. In some embodiments, the interior of the modules12even may have a thermal barrier that separates the front of a rack containing heat generating components (e.g., the servers, computers, switches, etc.) from the back of the rack. This barrier still further mitigates hot air flow into the cooler rack side.

After experimentation, the inventors discovered that orienting the modules12so that their air exhausts direct air inwardly toward the interior region22enables more efficient air flow and cooler module temperatures. Among other benefits, this module formation mitigates the volume of exhausted air that recycles through the air flow systems of neighboring modules12, and increases the efficiency of the air movers24directing air to the air outlet20B/exhaust side of each module12due to limited wind resistance. In addition, the inventors recognized that in many instances, this configuration allows the heated air time to rise high enough before the wind directs it back toward an air inlet20A. Ideally, by the time the wind has taken heated air and directed it towards an intake, that heated air is too high to be effectively drawn back into the air inlet20A. Even with extremely high winds, however, the interior region22at least in part protects the exhaust pressure and velocity characteristics to some extent, enabling more effective operation.

Some embodiments orient the air movers24themselves (e.g., blowers) or configure the air movers24at the air outlet20B to direct heated outlet air upwardly. For example, the air movers24at or near the air outlet20B may direct air straight into the interior region22(i.e., horizontal to the base of the module12), or upwardly at an angle of 1 or more degrees (e.g., up to 90 degrees from the horizontal). Satisfactory angles may include 10-45 degrees, 45-60 degrees, 60-90 degrees, or 5-90 degrees. To optimize airflow, the air movers24orient their outlet air stream to intersect that of one or more of the air streams from another module12forming the interior region22. As such, the air streams combine and, with their inherent heat, flow upwardly at a more desirable rate. Logic or other components also may automatically or dynamically adjust the angle of the air mover outlet stream to optimize cooling. Among other things, the angle can be a function of the weather, the operation of other modules12in its set of modules12(the set of modules12referred to as a “module set31”), the components being cooled, and environment. Moreover, in addition to being movable in the Z-direction (i.e., vertically), the air movers24may be movable in the X/Y plane (i.e., horizontally) or along all three axes.

As noted, a set of three or more modules12are oriented relative to each other to form the noted interior region22. While being open to the sky, these modules12are positioned not to form a laterally closed interior region22. Instead, in preferred embodiments and as shown in various figures, adjacent modules12are spaced apart so that they form lateral spaces38. As such, the modules12may be considered to at least in part form a circumferentially open space that defines the interior region22. It should be noted that circumferentially open implies that the region around the module set31has at least one opening and is not necessarily rounded (i.e., it can be a rectilinear shape or other shape, as discussed below).

More specifically, in the examples shown in various figures, each module12is considered to be adjacent to and between two other modules12. This adjacency is open, however, to form the lateral spaces38. These lateral spaces38may be considered to be formed by the closest portions of the modules12to each other. For example, top two modules12(from the perspective of the drawing) schematically shown inFIG.3Ahave adjacent vertical edges next to, but spaced apart from, each other. These two edges laterally open the interior region22and at least in part form the lateral space38between the top two modules12. The bottom two modules12in this figure have the same relationship and, as shown, each module12has another lateral space38on its other side. Accordingly, the adjacent housing portions may be considered to form the lateral spaces38. As such, the lateral spaces38may be considered to end at the respective roofs26of the modules12. The overhangs, if any such as that shown inFIG.2, may extend higher or into the lateral space38.

The inventors discovered that closing the interior region22undesirably may produce a pressure differential that causes the “chimney effect.” Instead of that, however, in the absence of different pressures at the air outlets20B, illustrative embodiments mitigate significantly different pressures between the top of the interior region22and the lower portions of the interior region22. In other words, ignoring the air outlet pressures, the pressure within the inlet region preferably is about the same as or close to that of the environment. As such, the lateral spaces38between modules12were determined to provide the desired benefit of efficiently removing outlet air. This pressure equalization configuration has delivered satisfactory results that provide an improved benefit in various environments when compared to potential designs without the lateral spaces38(closed lateral designs).

FIG.3Aschematically shows an exemplary arrangement of four modules12with their exhaust sides (i.e., a side with the air outlet20B), forming the interior region22in a diamond shape. In a similar manner,FIG.3Bshows multiple rectangular module sets31in another arrangement. In illustrative embodiments, with rectangular or similar housings18, the wall of the module12having the exhaust side of each module12may be considered to form a plane, and the intersection of each such plane creates the boundaries of the interior region22. The boundary thus defined by the planes of the modules12forms a geometric shape (e.g., rectangle, diamond, pentagon, hexagon, ring, oval, or rhombus). In some embodiments, the shape created by the plane boundaries can be irregularly shaped. Indeed, while these planes intersect, the interior region22is not a laterally closed region—it has one or more openings.FIG.4Aschematically shows a plan view of four modules12organized with exhaust sides generally pointing toward the interior region22. The interior region22boundary created by the planes of each module12, in this example, resembles a rhombus or diamond.

More specifically, unlike other figures, for illustrative purposes,FIG.4Aexpressly shows this effective region with the planes extended by extension lines that are in the drawing only—these extension lines are in the drawings to simplify the discussion. These extension lines, when extended, show the intersection of the various planes and how the interior region22forms a plurality of concave regions, particularly at the intersections. Similar interior regions22also may be considered to be formed when the modules12do not have planar sides forming the interior region22.

A person of ordinary skill in the art will recognize that the boundary of the interior region22can be defined by three, four, or five or more modules12within the scope of the disclosure. For example, inFIG.4B, the interior region22is triangular. Alternatively, inFIG.4C, six modules12are oriented to form a hexagonal interior region22. As in other embodiments, these figures expressly show the exhaust sides of the modules12facing the noted interior region22, and the air inlet side, opposite the exhaust side, pointing away from the interior region22.

In preferred embodiments, the interior region22/modules12in the module set31forming the interior region22are in the shape of a diamond with the two modules12forming an acute angle forming an effective point. To enhance performance, this point is generally pointing in the direction of the prevailing wind of the environment in which the modules12are located. Specifically, that effective point preferably is aligned with an points in the general direction of the usual wind in the environment or region—i.e., the “prevailing wind” referring to the most common direction of the wind (e.g., wind blowing east to west).

Some embodiments also may have a flow diverter40(FIG.4A) within the interior region22configured to direct outlet air in a prescribed direction. For example, the flow diverter40may direct air upwardly. To that end, the flow diverter40may have surface features (e.g., concavities, convex surfaces, etc.), that direct fluid/air in the desired manner. As another example, the flow diverter40may have a pyramidal shape.

Some or all of the outlet air movers24thus may direct their air flow toward the flow diverter40in a prescribed manner, such as directly at the flow diverter40or indirectly at the flow diverter40. Some embodiments may direct the outlet air movers24to direct flow away from the flow diverter40. Thus, for these and other reasons, the flow diverter40may be positioned in the general center of the interior region22, or offset from the center. In some embodiments, a plurality of like or unlike flow diverters40can be deployed within the interior region22to provide a more complex flow pattern. These flow diverters40can cooperate as if a single flow diverter40, or operate independently as specified by the data center requirements.

While modules12preferably form the interior region, some embodiments may use one or more natural and/or artificial structure(s) to in-part form/define the interior region22. For example, among other things, a set of rocks, a set of trees, a brick or wood wall, an empty module housing18, trailer, or other object can form a portion of the boundary of the interior region22.

In alternative embodiments, a single module12can be constructed in a geometric shape (or irregular shape) as discussed above with an interior region22that can perform a similar function. For example, this embodiment of the single module12may form a toroid, diamond, rhombus, etc., with an open interior region22.

The inventors discovered that this configuration of modules12also reduces the resulting noise from the air outlet20B. Specifically, air expelling through the air exhaust side of the module12creates substantial amounts of noise at the site of the data center10—air expelling into an uncontrolled environment can cause this issue. Mitigating noise by facing the exhaust side of each module12in the arrangement toward the interior region22—so air flow can be managed after expelled via the outlet—thus favorably reduces exhaust noise throughout the data center10.

In other embodiments, the air outlet20B on one or more of the modules12may be on a different part of the module, such as at the top of the module12. Some such embodiments may have air moving devices directing flow toward the interior region22. As with other embodiments, the interior region22is formed by one wall of each module12—in this case, an interior wall without the air outlet20B. In other embodiments, the air outlet20B can be at/in different areas of different modules12. For example, one module12can have the air outlet20B on its top/roof26while others may have the air outlet20B on the interior facing wall.

Returning toFIG.3B, the data center10of this example may be considered to have module sets31that each forms an interior region22. Each set31may be formed from modules12that are identical to or different than those of the other sets. Unlike the embodiment ofFIG.1, the sets of modules12are offset from each other in a non-linear pattern. In other words, this plurality of module sets31do not form a straight line of three or more module sets31—instead, it is more of a zig-zag pattern. This arrangement beneficially spaces apart the module sets31to minimize the heated outlet air from being fed into air inlet(s)20A of a neighboring module set31. For example, the far three sets starting from right to left may be identified as first, second and third module sets31. If positioned too close together, it is more likely that heated air from any of those sets may feed into the inlet(s) of the other. Rather than waste real estate, however, this data center10positions the second module set31diagonally or otherwise offset in a manner that minimizes the undesired hot air feedback from the other two module set(s)31. Thus, the first and third module sets31are far apart to minimize feedback risk while the second module set31is offset to mitigate its impact to or from the first and third module sets31.

FIG.5schematically shows, as arrows, the air flow of various embodiments of the invention. The arrows in this figure depict exemplary air flow pointing in the direction that air runs through the modules12. The colored background ofFIG.5is coordinated to a temperature legend depicting the various temperatures of the air as it flows through the modules12. As air enters the module12, the air movers24circulate the air within the module12and direct it through the air outlet20B into the interior region22. The modules12thus receive a fresh air flow through the externally-facing air inlet20A and, as shown and discussed above, the air outlet20B of each module12is directed toward the air outlets20B of the other modules12. As noted, in preferred embodiments, the interior region22is an open air region with the noted lateral spaces38. In other words, the interior region22is at least partly uncovered or otherwise unconfined beyond the planar geometric shape created substantially by the modules12. A person skilled in the art will appreciate that the interior region22also can be partially or fully covered or otherwise contained. Moreover, in some embodiments, the modules12and/or interior region22can have walls or other fluid directing devices to further optimize airflow or serve another purpose (e.g., heat elements for water, turn turbines, turn a mill, etc.). In fact, some embodiments can use a wall or other non-module structure as one or more units that form the interior region22. For example, the module set31ofFIG.5could have two modules (e.g., the top and bottom modules in the figure), and two walls or empty shells (e.g., the left and right structures).

FIG.6schematically shows another visualization of air flow in illustrative embodiments. The temperature and flow of the air in this drawing is represented by lines that are color-coordinated to a temperature legend to reflect temperature changes. As shown and discussed above, cooler air flows into the modules12through the air inlet sides and out into the interior region22from the air outlets20B. The temperature of the air increases as it flows through/around the processing devices within the module12, and is ultimately expelled as hot air from the exhaust side of the module12. The orientation of the modules12creates an effective stream of combined exhaust flow of hot exhausted air that rises from the interior region22into the environment. In various embodiments, the exhausted air is pushed away by wind and/or natural airflow. The buffers36on the air inlet side of each module12and module set configurations mitigate the amount of exhausted air undesirably recycled through the air flow system of the modules12. Moreover, as noted above, a scaffold on the module roof26or other region, which directs air flow, with or without baffles, can mitigate hot air from mixing with the colder air on another physically spaced apart area of the system.

FIG.7schematically shows an exemplary representation of air velocity in various embodiments. This type of representation may show how the interior region22is significantly shielded from external wind (e.g., the external wind may have a negligible impact on the interior region22). The color of the air is coordinated to a speed legend. The formation of the modules12allows the wind to flow directly into the air inlet side of some of the modules12, while the exhaust side of each module12is at least partially shielded from wind by the other modules12in the formation, thus bolstering the efficiency of the air movers24expelling air from the modules12. The combined exhaust air rises and may be drawn away by the wind.

FIG.8schematically shows a series of module set formations while the wind is blowing in a different direction from that ofFIG.7. This figure also shows how relatively closely spaced modules12tightly protect from the wind, and how the air inlet(s)20A of neighboring modules12are protected from the exhaust. This also shows diamond shaped module sets31/interior regions22with the acute sides generally aligned with (or pointing into) the prevailing winds.

As such, the air flow is depicted by lines that are color-coordinated to a temperature legend. In a manner similar to other figures, the wind blows into the air inlet sides of the modules12in each formation, while the exhaust sides expel hot air into the interior region22, creating the noted exhaust. The wind further pushes the stream of hot exhaust over and away from the series of module formations. The modules12on the back side of the formation thus avoid intake of hot exhausted air, increasing the efficiency of the cooling system within each module set31within the data center10.

FIG.9shows a process of convectively cooling the data center10discussed above (and similarly structured other data centers) in accordance with illustrative embodiments. It should be noted that this process is simplified from a longer process that normally would be used to cool components in the data center10. Accordingly, the process may have additional steps that those skilled in the art likely would use. In addition, some of the steps may be performed in a different order than that shown, or at the same time. Those skilled in the art therefore can modify the process as appropriate.

Moreover, as noted, many of the materials and structures noted are but one of a wide variety of different materials and structures that may be used. Those skilled in the art can select the appropriate materials and structures depending upon the application and other constraints. Accordingly, discussion of specific materials and structures is not intended to limit all embodiments.

The process ofFIG.9begins at step900, in which one or more modules12in a module set31receive cool air at their respective air inlets20A. This air then is forced over and about various heat producing components (e.g., servers, computers, etc.) to provide convective cooling (step902). To that end, the modules12each have internal fluid/air flow equipment (e.g., air movers24or air guides) within the module interiors to direct air in a desired manner. As the air passes through the module12and over heat producing equipment, it absorbs heat, and is forced out of the module12, via the air outlets20B, into the interior region22(step904). Although the convectively cooling air may make some turns within the module interior, the air inlet20A and air outlet20B preferably form a substantially straight line, or at least a portion of the air inlet20A and a portion of the air outlet20B form a straight line. Other embodiments, however, may not form such a straight line.

Those skilled in the art may use various embodiments in areas other than data centers10. For example, various embodiments may be used in manufacturing factories, chemical production plants, semiconductor fabs, office buildings, etc. Such other embodiments, however, likely require customization not discussed above.

The embodiments of the invention described above are intended to be merely exemplary; numerous variations and modifications will be apparent to those skilled in the art.