Patent Application
20150319889
Various embodiments of the present invention relate to liquid cooling mediums employed to immersion-cool electronic hardware devices, such as data centers. Other aspects of the invention concern liquid cooling mediums having a balance of flash point and viscosity.
Enterprise Data Center (“EDC”) facilities are physical locations housing multiple servers. Servers are generally stacked in racks in which are also mounted various computing devices, such as hard-drive arrays, network routers, data acquisition equipment, and power supplies. To deliver consistent and reliable performance, a primary goal for EDCs is adequate temperature control of the various heat generating components of the rack. Traditionally, the racks have been cooled by forced-air convection using air circulating devices, such as fans, selectively placed to maximize air flow. Air within the EDC usually circulates through a heat exchanger for cooling the air (a vapor-cycle refrigeration or chilled water coil) before entering the rack. In some EDCs, the heat exchanger is mounted at the rack to provide a rack-level cooling of the air that enters the server.
In 2005, EDCs in the United States accounted for about 1.2% of all electricity consumed, and was expected to double by 2011. It has furthermore been estimated that the EDC population globally, if combined, would be the 6th largest energy-consuming community in the world. More than one third of EDC electricity consumption is dedicated to cooling. In addition to the high impact of cooling costs on the overall EDC budget and the trend to reduce greenhouse gas emissions, energy efficiency optimization has become critical with the chiller cooling capacity approaching maximum utilization. In addition, further expansion of the EDCs will require major investment in cooling capacity expansion. Accordingly, although advancements have been made in the field of electronic hardware device cooling, improvements are still desired.
One embodiment is an apparatus comprising:
wherein said electronic hardware device is at least partially submerged in said liquid cooling medium,
wherein said liquid cooling medium has a flash point of at least 190° C., as determined according to ASTM D92,
wherein said liquid cooling medium has a viscosity of 27 centistokes (“cSt”) or less at 40° C., as determined according to ASTM D445.
Various embodiments of the present invention concern an apparatus comprising an electronic hardware device at least partially submerged in a liquid cooling medium, where the liquid cooling medium has a certain combination of properties. In various embodiments, the liquid cooling medium can have a flash point of at least 190° C. while simultaneously having a viscosity of 27 centistokes (“cSt”) or less. In certain embodiments, the liquid cooling medium can comprise saturated medium chain triglycerides having an average fatty acid carbon chain length ranging from 6 to 12 carbon atoms.
The term “liquid cooling medium” denotes a composition that is liquid at room temperature and standard pressure which is suitable for use as an immersion coolant for an electronic hardware device, such as a server. As known in the art, liquid cooling mediums generally have low viscosity, are non-toxic, chemically inert, and do not promote corrosion of equipment in which the liquid cooling medium is employed. Additionally, liquid cooling mediums may generally have higher heat capacities relative to other cooling mediums, such as air (e.g., 1.67 joules per gram per Kelvin (“J/g/K”) compared to 1.01 J/g/K).
As noted above, the liquid cooling medium can have a flash point of at least 190° C. In various embodiments, the liquid cooling medium can have a flash point of at least 192° C., at least 195° C., at least 200° C., or at least 205° C. Furthermore, in any one of such embodiments, the liquid cooling medium can have a flash point up to 300° C., up to 280° C., or up to 270° C. Flash points provided herein are determined according to ASTM International (“ASTM”) method D92 using a Cleveland open cup apparatus. In this method, about 70 milliliters (“mL”) of test specimen is filled into a test cup, The temperature of the specimen is increased quickly initially and then slowly and at a constant rate close to the flash point. A test flame is passed across the cup at specified intervals. The flash point corresponds to the lowest liquid temperature at which application of the test flame leads to the ignition of the vapors of the test specimen. For the fire point determination (discussed below), the test continues until the test flame leads to ignition and also sustains burning for a minimum of 5 seconds.
As noted above, the liquid cooling medium can have a viscosity of 27 cSt or less. In various embodiments, the liquid cooling medium can have a viscosity of less than 27 cSt, less than 25 cSt, less than 23 cSt, less than 20 cSt, less than 18 cSt, or less than 15 cSt. Furthermore, in any one of such embodiments, the liquid cooling medium can have a viscosity of at least 5 cSt, at least 7 cSt, or at least 10 cSt. Viscosities provided herein are determined according to ASTM D445 test method for kinematic viscosity at a temperature of 40° C. In this method, the time for a fixed volume of fluid to flow under gravity through the capillary of a calibrated viscometer is measured at a controlled temperature. The kinematic viscosity is defined as the product of the measured flow time and the calibration constant of the viscometer.
As noted above, in various embodiments, the liquid cooling medium can have a combination of certain flash points and viscosities. Thus, in one or more embodiments, the liquid cooling medium can have a flash point of at least 190° C., at least 192° C., at least 195° C., at least 200° C., or at least 205° C., while also having a viscosity of 27 cSt or less, or less than 27 cSt, less than 25 cSt, less than 23 cSt, less than 20 cSt, less than 18 cSt, or less than 15 cSt. In any of such embodiments, the liquid cooling medium can have a flash point up to 300° C., up to 280° C., or up to 270° C., while having a viscosity of at least 5 cSt, at least 7 cSt, or at least 10 cSt.
In various embodiments, the liquid cooling medium can have a fire point of at least 210° C., at least 215° C., or at least 220° C. In such embodiments, the liquid cooling medium can have a fire point up to 320° C., up to 310° C., up to 300° C., or up to 290° C. Fire points are determined herein according to ASTM D92, as described above.
In various embodiments, the liquid cooling medium can have a thermal conductivity ranging from 0.12 to 0.14 watts per meter Kelvin (“W/m·K”). Thermal conductivity is determined at 40° C. according to procedure provided in the Test Methods section, below.
Any liquid cooling medium having the above-described properties can be employed in the various embodiments described herein. As noted above, in certain embodiments, the liquid cooling medium can comprise medium-chain triglycerides (“MCTs”). As known in the art, a “triglyceride” is a triester of glycerol and three fatty acids, and triglycerides are often found in natural sources, such as animal fats and vegetable oils. The term “medium chain” denotes triglycerides having fatty acid carbon-chain lengths ranging from 6 carbon atoms to 12 carbon atoms, including the carbonyl carbon. Thus, for example, MCTs suitable for use herein can be triesters of glycerol and fatty acids selected from the group consisting of caproic acid (C6), caprylic acid (C8), capric acid (C10), and lauric acid (C12). In various embodiments, the MCTs are saturated (i.e., containing no carbon-carbon double bonds), although trace amounts of unsaturated compounds (e.g., less than 10 parts per million) are acceptable. In an embodiment, MCTs suitable for use can have an average fatty acid carbon chain length in the range of from 8 to 10 carbon atoms. Additionally, the MCTs, when either used alone or as a component in a multi-component liquid cooling medium, can comprise free fatty acids of less than 1 weight percent (“wt %”), less than 0.5 wt %, or less than 0.01 wt %, based on the entire liquid cooling medium weight.
In various embodiments, the MCTs comprise a mixture of C8 triglycerides and C10 triglycerides. In such embodiments, the C8 triglycerides can constitute in the range of from 10 to 90 wt %, from 20 to 85 wt %, from 40 to 80 wt %, or from 50 to 60 wt % of all MCTs based on the entire MCT weight. Additionally, the C10 triglycerides can constitute in the range of from 10 to 90 wt %, from 15 to 80 wt %, from 30 to 70 wt %, or from 40 to 50 wt % of all MCTs based on the entire MCT weight. In an embodiment, the MCT can be a blend of C8 and C10 triglycerides comprising 56 wt % C8 triglycerides and 44 wt % C10 triglycerides.
In various embodiments, the MCTs comprise a mixture of C6, C8, C10, and C12 triglycerides. In such embodiments, the C6 triglycerides can constitute in the range of from 0.5 to 10 wt %, or from 1 to 5 wt % of all MCTs based on the entire MCT weight. Further, the C8 triglycerides can constitute in the range of from 50 to 80 wt %, or from 60 to 70 wt % of all MCTs based on the entire MCT weight. Additionally, C10 triglycerides can constitute in the range of from 20 to 40 wt %, or from 25 to 35 wt % of all MCTs based on the entire MCT weight. In such embodiments, C12 triglycerides can constitute in the range of from 0.5 to 10 wt %, or from 1 to 5 wt % of all MCTs based on the entire MCT weight.
Examples of suitable commercially available MCTs include the NEOBEE™ line of MCTs (e.g., NEOBEE™ 1053 and NEOBEE™ M-20) available from Stepan Company, Northfield, Ill., USA.
In various embodiments, the liquid cooling medium can comprise a mixture of any one or more of the above-described MCTs and at least one mineral oil. As used herein, “mineral oil” denotes a mixture of primarily alkanes generally ranging from C15 to C40 derived from a non-vegetable source, such as petroleum. Mineral oils generally have low flash points, ranging from about 140° C. up to 185° C. Thus, mineral oils alone are not generally desirable for use as liquid cooling mediums. However, in combination with MCTs, mineral oils can combine to form a liquid cooling medium having the above-described properties. In various embodiments, the mineral oil selected for combination with an MCT has a flash point near the upper limit typically found in mineral oils, such as from 175 to 185° C., from 180 to 185° C., or about 185° C.
When a mixture of MCTs and mineral oil is used as the liquid cooling medium, the MCTs can constitute in the range of from 10 to 90 wt %, from 15 to 85 wt %, from 20 to 80 wt %, or from 40 to 60 wt % of the liquid cooling medium based on the entire liquid cooling medium weight. Additionally, the mineral oil can constitute in the range of from 10 to 90 wt %, from 15 to 85 wt %, from 20 to 80 wt %, or from 40 to 60 wt % of the liquid cooling medium based on the entire liquid cooling medium weight. In various embodiments, the MCTs and mineral oil can be present in the liquid cooling medium at a weight ratio ranging from 2:1 to 6:1, from 3:1 to 5:1, or about 4:1 MCT-to-mineral oil.
Examples of suitable commercially available mineral oils include UNIVOLT™ N 61B, produced by ExxonMobil Chemical Company, Houston, Tex., USA; or DIALA™ AX, produced by Shell Oil Company, Houston, Tex., USA.
In various embodiments, the liquid cooling medium can comprise a mixture of any one or more of the above-described MCTs and at least one synthetic ester. As used herein, “synthetic ester” denotes a fluid produced by the reaction of an alcohol with an organic (e.g., carboxylic) acid. Synthetic esters generally have higher flash points, but may suffer from unacceptably high viscosity (e.g., 28 cSt or more at 40° C.). Thus, synthetic esters alone are not generally desirable for use as liquid cooling mediums. However, in combination with MCTs, synthetic esters can combine to form a liquid cooling medium having the above-described properties. In various embodiments, the synthetic ester selected for combination with MCTs has a viscosity near the lower limit typically found in synthetic esters, such as from 28 to 38 cSt, from 28 to 33 cSt, or about 28 cSt.
When a mixture of MCTs and synthetic ester is used as the liquid cooling medium, the MCTs can constitute in the range of from 10 to 90 wt %, from 15 to 85 wt %, from 20 to 80 wt %, or from 40 to 60 wt % of the liquid cooling medium based on the entire liquid cooling medium weight. Additionally, the synthetic ester can constitute in the range of from 10 to 90 wt %, from 15 to 85 wt %, from 20 to 80 wt %, or from 40 to 60 wt % of the liquid cooling medium based on the entire liquid cooling medium weight.
An example of a suitable commercially available synthetic ester includes MIDEL™ 7131, produced by M&I Materials Ltd., Manchester, UK.
In various embodiments, the liquid cooling medium can comprise a mixture of any one or more of the above-described MCTs and at least one vegetable oil. As used herein, “vegetable oil” denotes a composition primarily comprised of triglycerides, which are triesters of three fatty acids with glycerol, but generally comprise longer-chain fatty acid moieties (e.g., C18) as compared to MCTs. Vegetable oils generally have higher flash points, but may suffer from unacceptably high viscosity (e.g., 40 cSt or more at 40° C.). Thus, vegetable oils alone are not generally desirable for use as liquid cooling mediums. However, in combination with MCTs, vegetable oils can combine to form a liquid cooling medium having the above-described properties. In various embodiments, the vegetable oil selected for combination with an MCT has a viscosity near the lower limit typically found in vegetable oils, such as from 30 to 50 cSt, from 35 to 45 cSt, or about 40 cSt.
When a mixture of MCTs and vegetable oil is used as the liquid cooling medium, the MCTs can constitute in the range of from 10 to 90 wt %, from 15 to 85 wt %, from 20 to 80 wt %, or from 40 to 60 wt % of the liquid cooling medium based on the entire liquid cooling medium weight. Additionally, the vegetable oil can constitute in the range of from 10 to 90 wt %, from 15 to 85 wt %, from 20 to 80 wt %, or from 40 to 60 wt % of the liquid cooling medium based on the entire liquid cooling medium weight. In various embodiments, the MCTs and vegetable oil can be present in the liquid cooling medium at a weight ratio ranging from 3:1 to 1:1 MCT-to-vegetable oil.
Specific types of vegetable oils suitable for use herein include, but are not limited to, sunflower oil, canola oil, and soybean oil. In an embodiment, the vegetable oil is sunflower oil.
In one or more embodiments, the liquid cooling medium can comprise a polyalkylene glycol. “Polyalkylene glycol” denotes an oligomer or polymer primarily comprised of polymerized alkylene oxide (e.g., ethylene oxide). Examples of suitable polyalkylene oxides include polyethylene oxide, polypropylene oxide, and polybutylene oxide. When a polyalkylene glycol is employed in the liquid cooling medium, it can constitute at least 50 wt %, at least 70 wt %, at least 90 wt %, at least 99 wt %, or all of the liquid cooling medium, based on the entire liquid cooling medium weight.
Suitable polyalkylene glycols can have a weight averaged molecular weight (“Mw”) ranging from 500 to 1,000 g/mol, from 600 to 800 g/mol, or from 650 to 750 g/mol. In an embodiment, the polyalkylene glycol can have an Mw of about 700 g/mol. Additionally, suitable polyalkylene glycols can have a density ranging from 0.80 to 1.0 g/mL, from 0.85 to 0.98 g/mL, from 0.90 to 0.94 g/mL, or from 0.91 to 0.93 g/mL. In an embodiment, the polyalkylene glycol can have a density of about 0.92 g/mL.
Examples of suitable commercially available polyalkylene glycols include UCON™ OSP and Synalox OA produced by The Dow Chemical Company, Midland, Mich., USA; and PLURIOL™ polyalkylene glycols, available from BASF Corporation, Florham Park, N.J., USA.
In one or more embodiments, the liquid cooling medium can comprise a paraffinic oil. “Paraffinic oil” denotes a class of mineral oils based on n-alkanes, having a low content of aromatic hydrocarbons. Examples of suitable paraffinic oils include any paraffinic oil meeting the above-described flash point and viscosity requirements. When a paraffinic oil is employed in the liquid cooling medium, it can constitute at least 50 wt %, at least 70 wt %, at least 90 wt %, at least 99 wt %, or all of the liquid cooling medium, based on the entire liquid cooling medium weight.
Examples of suitable commercially available paraffinic oils include PARAMOUNT™ 1001 and PARALUX™ 1001, both produced by Chevron Corporation, San Ramon, Calif., USA.
In any of the foregoing embodiments, when the liquid cooling medium employed is a blend of two or more components, the blend can be prepared by any known or hereafter discovered methods in the art for blending two liquid components. For example, multiple liquid components can be mechanically blended using stirrers. In various embodiments, the two or more components making up the liquid cooling medium are miscible.
As noted above, the liquid cooling medium can be employed to cool an electronic hardware device, such as in a data center. In an embodiment, the electronic hardware device can be a computer device or component (e.g., a computer server). Specific examples of electronic hardware devices that can be employed include computer servers, server motherboards, microprocessors and other heat-generating electronic devices.
In order to effect such cooling, the electronic hardware device can be placed in physical contact with the liquid cooling medium. For example, the electronic hardware device can be partially, at least partially, or completely submerged into the liquid cooling medium.
Specific cooling systems employing at least partial submersion in the liquid cooling medium are varied. By way of example, in one embodiment, the electronic hardware device is completely immersed in an individually sealed bath of liquid cooling medium. In this embodiment, the liquid cooling medium passively transfers heat away from the electronic hardware device to an integrated heat exchanger formed by the wall of the bath where water is continuously circulated and cooled. In another embodiment, a server motherboard can be completely immersed in an individually sealed bath of liquid cooling medium. The liquid cooling medium is then pumped through sealed server cases and circulated through a radiator attached to the pump acting as a heat exchanger. In still another embodiment, an entire rack of servers can be immersed in a tank filled with liquid cooling medium. In this embodiment, the liquid cooling medium can circulate through an outdoor radiator where the heat is exchanged directly to exterior air.
Specific examples of such cooling systems can be found, for example, in U.S. Pat. No. 7,403,392 to Hardcore Computer, Inc, and U.S. Published Patent Application No. 2011/0132579 to Green Revolution Cooling, Inc.
Fire point is determined according to ASTM D92.
Flash point is determined according to ASTM D92.
Thermal conductivity is determined according to ASTM D5930 by subjecting the sample to an axial temperature gradient. By measuring the temperature difference across the sample along with the output from the heat flux transducer, thermal conductivity of the sample can be determined.
Viscosity is determined according to ASTM D445 at 40° C.
Analyze three Comparative Samples (CS A-C) according to the above-described Test Methods. CS A is 100 wt % mineral oil sold under the trade name UNIVOLT™ N 61B, which is available from ExxonMobil Chemical Company, Houston, Tex., USA. UNIVOLT™ N 61B is a 90 to 100% hydrogenated light naphthenic distillate. CS B is 100 wt % sunflower oil obtained from Saipol Agro Industrial Company, Paris, France. CS C is 100 wt % of a synthetic ester sold under the trade name MIDEL™ 7131, which is produced by M&I Materials Ltd., Manchester, UK. MIDEL™ 7131 comprises fatty acid, C5-10 (linear and branched), mixed esters with pentaerythritol. Results of the analyses are provided in Table 1, below.
As can be seen from the results shown in Table 1, while mineral oil (CS A) provides desirably low viscosity, it also exhibits an undesirably low flash point. Conversely, sunflower oil (CS B) and synthetic ester (CS C) alone have desirably high flash points, but unacceptably high viscosities.
Analyze two Samples (S1 and S2) according to the above-described Test Methods. S1 is 100 wt % medium-chain triglycerides, sold under the trade name NEOBEE™ 1053 by Stepan Company, Northfield, Ill., USA. NEOBEE™ 1053 is a saturated caprylic (C8)/capric (C10) triglyceride. NEOBEE™ 1053 contains 56 percent saturated caprylic (C8) fatty acid chains, and 44 percent saturated capric (C10) fatty acid chains. S2 is 100 wt % medium-chain triglycerides sold under the trade name NEOBEE™ M-20 by Stepan Company, Northfield, Ill., USA. NEOBEE™ M-20 contains 1 percent C6 fatty acid chains, 1 percent C12 fatty acid chains, 68 percent C8 fatty acid chains, and 30 percent C10 fatty acid chains. Results of the analyses are provided in Table 2, below.
As shown in Table 2, both of the MCT samples provide superior viscosity (e.g., less than about 28 cSt) while simultaneously providing excellent flash points (e.g., at least about 190° C.).
Prepare two Samples (S3-S4) containing MCT and mineral oil according to the compositions provided in Table 3, below. Samples S3-S4 are prepared by mixing the two components via magnetic stirring in a closed jar at 50° C. for 15 minutes. The MCT employed in each of Samples S3 and S4 is NEOBEE™ 1053, as described above in Example 2. The mineral oil in Samples S3 and S4 is the mineral oil supplied by Univolt, as described above in Example 1.
Analyze Samples S3 and S4 according to the Test Methods provided above. Results are provided in Table 3, below.
As seen in Table 3, although mineral oil alone (CS A, Table 1) does not provide the appropriate combination of low viscosity and high flash point, the mixtures of MCT with mineral oil do provide such a combination. It is noted that S4 only achieved a flash point of 170° C.; however, this is a significant improvement over the flash point of the Univolt mineral oil alone, which is 154° C., as shown by CS A in Table 1, above.
Prepare five Samples (S5-S9) containing MCT and sunflower oil according to the compositions provided in Table 4, below. Sample S5-S9 are prepared by mixing the two components via magnetic stirring in a closed jar at 50° C. for 15 minutes. The MCT employed in Samples S5-S7 is NEOBEE™ 1053, as described above in Example 2. The MCT employed in Samples S8 and S9 is NEOBEE™ M-20, as described above in Example 2. The sunflower oil in Samples S5-S9 is the same as the sunflower oil described in Example 1, above.
Analyze Samples S5-S9 according to the Test Methods provided above. Results are provided in Table 4, below.
As seen in Table 4, although sunflower oil alone (CS B) does not provide the appropriate combination of low viscosity and high flash point, the mixtures of MCT with sunflower oil all provide superior viscosities and flash points.
Prepare three Samples (S10-S12) containing MCT and synthetic ester according to the compositions provided in Table 5, below. Sample S10-S12 are prepared by mixing the two components via magnetic stirring in a closed jar at 50° C. for 15 minutes. The MCT employed in Samples S10-S12 is NEOBEE™ 1053, as described above in Example 2. The synthetic ester in Samples S10-S12 is MIDEL™ 7131, as described in Example 1, above.
Analyze Samples S10-S12 according to the Test Methods provided above. Results are provided in Table 5, below.
As seen in Table 5, although synthetic ester alone (CS C) does not provide the appropriate combination of low viscosity and high flash point, the mixtures of MCT with synthetic ester all provide superior viscosities and flash points.
Sample 13 (S13) is 100 wt % polyalkylene glycol (“PAG”). Specifically, S13 is UCON OSP-18, an oil-soluble PAG base fluid technology from Dow Chemical. Analyze Sample S13 according to the Test Methods provided above. S13 has a viscosity of 18.0 cSt, a flash point of 204° C., a fire point of 240° C., a heat capacity of 1.96 J/g/° C., and a thermal conductivity of 0.14 w/m·K.
Sample 14 (S 14) is 100 wt % paraffinic oil. Specifically, S14 is PARAMOUNT™ 1001, available from Chevron. S14 has a viscosity of 20.4 cSt and a flash point of 212° C.
The present application claims the benefit of U.S. Provisional Application No. 61/756,019, filed on Jan. 24, 2013.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2013/075670 | 12/17/2013 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 61756019 | Jan 2013 | US |
