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1. Field of the Invention
The invention relates to micro-channel cooling. More specifically, the invention relates to micro-channel cooling for electronics cooling rooms and cabinets in precision cooling applications.
2. Description of Related Art
Increased demands are being made on cooling systems for electronic equipment in precision cooling applications. Precision cooling applications include mission-critical systems, such as data centers with cooled rooms and cooled cabinets for electronic equipment, medical equipment centers and operating rooms, and the like. If the equipment is not sufficiently cooled, the internal temperature of the electronic components in the equipment dramatically increases over relatively short periods of time, which may result in significantly reduced system performance and, in some cases, component or total system failure. The additional power and capabilities combined with increased density of electronics placement have stressed the capabilities of conventional cooling schemes for such precision cooling applications. Even where system performance is not compromised, inefficient cooling may unnecessarily increase the cost of cooling the equipment and shorten the lifetime of the equipment.
Typically, a refrigeration system uses conventional fin-and-tube condenser coils to dissipate heat generated from other portions of the refrigeration system, such as the compressor and evaporator, by passing the refrigerant through the condenser coils. The refrigerant is then circulated back to other system portions in a closed loop system. The condenser coil must be sized to absorb the heat for the system to maintain continuous operation. However, fin-and-tube condenser coils often have poor efficiencies in dissipating heat from the refrigerant passing through the coils. As a result, fin-and-tube condenser coils can be disproportionately large for the amount of heat they can dissipate from the refrigerant. The size also increases the amount of refrigerant which can have an environmental impact.
New and different methods are being investigated to increase the cooling capabilities to satisfactory levels. A recent innovation is the use of microchannel cooling technology to provide increase efficiencies. Microchannel technology uses cooling tubes subdivided into multiple channels for separating the cooling fluid into individual flow paths and increased energy transfer. A typical application for microchannel cooling has been in conduction cooling of electronic chips. An example is U.S. Pat. No. 6,903,929 in which an integrated circuit is thermally coupled to a pair of microchannel heat exchangers disposed on opposite sides of an integrated circuit die to cool the electronic components. Another example is seen in U.S. Pat. No. 6,986,382 in which a microchannel heat exchanger captures thermal energy generated from a heat source by passing fluid through selective areas of the interface layer that is preferably coupled to the heat source, such as electronic chips. In particular, the fluid is directed to specific areas in the interface layer to cool the hot spots and areas around the hot spots to create temperature uniformity across the heat source while maintaining a small pressure drop within the heat exchanger. A more recent application of microchannel technology has been applied to specific racks in cooling cabinets in U.S. Publ. No. 2006/0102322. At least one embodiment discusses a plurality of heat-generating objects, such as electronic circuit boards and hardware, that are situated vertically in an electronic cabinet or other enclosure, and a plurality of heat exchangers that are situated in the enclosure such that a heat exchanger is situated between adjacent heat generating objects in a spaced-apart relationship.
However, these examples are for cooling the electronic device or other source of heat in a specific portion of the refrigeration system, typically known as an “evaporator.” Different parameters apply for cooling the refrigerant by dissipating the heat of the cooling fluid in the refrigeration system portion typically known as the “condenser.” One microchannel application for a condenser portion of the refrigeration system is seen in U.S. Pat. No. 6,988,538 in which a condenser assembly can condense an evaporated refrigerant for use in a retail store refrigeration system. The condenser assembly includes at least one microchannel condenser coil including an inlet manifold and an outlet manifold. The patent discloses serial and parallel flow path arrangements of multiple microchannel condensers, and stacked and single layer systems of condensers.
Thus, there remains a need for a centralized microchannel cooling system for precision cooling applications.
The present disclosure provides a method, apparatus, and system for a centralized microchannel cooling system in precision cooling applications, such as mission-critical systems with data centers or cabinets or rooms with medical equipment. The microchannel condenser is designed to provide sufficient cooling for such applications by configuring multiple microchannel slabs together in a fashion that advantageously can increase the overall cooling abilities of multiple slabs not heretofore known. The system can provide a retrofit condenser for some existing precision cooling systems that have limitations on size, while satisfying cooling capacity requirements. The multiple slabs can be cooled by flowing a fluid such as air or a liquid across them. One or more microchannel slabs can be mounted horizontally, vertically, or in an inclined position. Further, the system can allow for multiple passes of refrigerants through the microchannel slabs.
The disclosure provides a cooling system for precision cooling for electronic equipment, comprising: an electronic equipment support structure adapted to support one or more heat generating electronic equipment; an evaporator in fluid communication with the support structure and adapted to provide cooling to the support structure; a compressor; and a microchannel condenser fluidicly coupled to the compressor and adapted to cool refrigerant from the compressor and dissipate heat from the refrigerant.
The disclosure further provides a method of precision cooling for electronic equipment, comprising: flowing a quantity of refrigerant through an evaporator to cool heat generating electronic equipment supported in an electronic equipment support structure; compressing the refrigerant through a compressor; cooling the refrigerant through a microchannel condenser; and flowing a quantity of air across fins in the microchannel condenser.
While the concepts provided herein are susceptible to various modifications and alternative forms, only a few specific embodiments have been shown by way of example in the drawings and are described in detail below. The figures and detailed descriptions of these specific embodiments are not intended to limit the breadth or scope of the concepts or the appended claims in any manner. Rather, the figures and detailed written descriptions are provided to illustrate the concepts to a person of ordinary skill in the art as required by 35 U.S.C. § 112.
One or more illustrative embodiments of the concepts disclosed herein are presented below. Not all features of an actual implementation are described or shown in this application for the sake of clarity. It is understood that the development of an actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's goals, such as compliance with system-related, business-related, and other constraints, which vary by implementation and from time to time. While a developer's efforts might be complex and time-consuming, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill in the art having benefit of this disclosure.
In at least one embodiment, the compressor 18 can be a fixed displacement compressor or advantageously a variable flow compressor, sometimes referred to as a modulated or digital scroll compressor. The variable flow compressor can allow the refrigeration system 16 to operate more efficiently in that the compressor can be modulated more closely to variable load conditions. For example, the modulation can be controlled by controlling the duty cycle of the compressor with a bypass valve that opens and closes to at least partially bypass the compression stage of the compressor.
The condenser 20 is used to cool the refrigerant, heated by the compressor compressing the refrigerant. Generally, the condenser 20 can be subdivided into one or more modules (herein “slabs”), so that refrigerant can flow through each of the slabs to control the amount of cooling from the refrigerant and hence head pressure on the refrigeration system. The condenser 20 can include, therefore, microchannel slabs 20A, 20B, 20C. Further, it is understood that the slabs can be mounted vertically as illustrated in
The expansion device 22, such as an expansion valve, can expand the refrigerant to a lower pressure and thermodynamically cool the refrigerant. The cooled refrigerant flows from the expansion device to the evaporator 24. The evaporator 24 is a heat exchanger that cools warmer air generated by the electronic equipment in the support structure and is therefore in fluid communication with the support structure. One or more fans 26 can move air across the surfaces of the evaporator 24 and increase the efficiency of the system 16. The evaporator 24 allows cool refrigerant flowing in the evaporator to cool warmer air or another medium flowing across the evaporator external surfaces. Conversely, the flowing medium transfers its higher heat into the refrigerant. In at least one embodiment, the evaporator 24 can be mounted vertically along the height of the cabinet 2.
The controller 30 can be used to control the flow of refrigerant through the system, the operation of the compressor, the operation of the fans, the operation of pumps, and other operational factors. Further, the controller 30 can control one or more valves (not shown) that control the flow of refrigerant through the condenser and particularly through one or more of the microchannel slabs.
An inlet refrigerant line 32 can provide the refrigerant to the microchannel condenser. If multiple slabs are used, the line 32 can provide the refrigerant to an inlet manifold 34 that then can provide the refrigerant to the slabs. Each slab 20A, 20B can include an inlet header 36A, 36B. The inlet headers 36A, 36B can include slab inlets 38A, 38B, respectively, where the inlet manifold 34 can be fluidicly coupled to the slab inlets. The refrigerant can flow into the slab through the slab inlets 38A, 38B and flow into an intermediate header 42A, 42B on the slabs 20A, 20B. When the slab is a multi-path slab, so that the refrigeration passes multiple times therethrough, the intermediate headers 42A, 42B can return the flow of refrigerant into a return path through the slab to an outlet. Baffles 40A, 40B on the slabs 20A, 20B can be used to separate the inlet headers 36A, 36B from outlet headers 44A, 44B on the slabs 20A, 20B, where the outlet headers 44A, 44B receive the return flow of refrigerant fluid from the intermediate headers 42A, 42B. The cooled refrigerant can exit the slabs through a slab outlet 46A, 46B on the slabs 20A, 20B and flow into an outlet manifold 48. The refrigerant can then flow into an outlet refrigerant line 50 to other portions of the refrigeration system, such as the expansion device 22 described in reference to
One or more of the slabs, such as slab 20A, can be designed to handle a variety of heat loads. For an exemplary cooled electronics cabinet having a design maximum heat load of 28 kilowatts, an exemplary design for at least one slab is described in
If the slab is a multi-pass slab, such as described in reference to
The thickness of the slab 20A can be about 0.78″ (20 mm), as shown in
The various methods and embodiments of the invention can be included in combination with each other to produce variations of the disclosed methods and embodiments, as would be understood by those with ordinary skill in the art, given the understanding provided herein. Also, various aspects of the embodiments could be used in conjunction with each other to accomplish the understood goals of the invention. Also, the directions such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions and orientations are described herein for clarity in reference to the figures and are not to be limiting of the actual device or system or use of the device or system. The term “coupled,” “coupling,” “coupler,” and like terms are used broadly herein and can include any method or device for securing, binding, bonding, fastening, attaching, joining, inserting therein, forming thereon or therein, communicating, or otherwise associating, for example, mechanically, magnetically, electrically, chemically, directly or indirectly with intermediate elements, one or more pieces of members together and can further include without limitation integrally forming one functional member with another in a unity fashion. The coupling can occur in any direction, including rotationally. Unless the context requires otherwise, the word “comprise” or variations such as “comprises” or “comprising”, should be understood to imply the inclusion of at least the stated element or step or group of elements or steps or equivalents thereof, and not the exclusion of a greater numerical quantity or any other element or step or group of elements or steps or equivalents thereof. The device or system may be used in a number of directions and orientations. Further, the order of steps can occur in a variety of sequences unless otherwise specifically limited. The various steps described herein can be combined with other steps, interlineated with the stated steps, and/or split into multiple steps. Additionally, the headings herein are for the convenience of the reader and are not intended to limit the scope of the invention.
The invention has been described in the context of various embodiments and not every embodiment of the invention has been described. Apparent modifications and alterations to the described embodiments are available to those of ordinary skill in the art. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived of by the Applicant, but rather, in conformity with the patent laws, Applicant intends to protect all such modifications and improvements to the full extent that such falls within the scope or range of equivalent of the following claims.
Further, any references mentioned in the application for this patent as well as all references listed in the information disclosure originally filed with the application are hereby incorporated by reference in their entirety to the extent such may be deemed essential to support the enabling of the invention. However, to the extent statements might be considered inconsistent with the patenting of the invention, such statements are expressly not meant to be considered as made by the Applicant(s).
This application claims the benefit of U.S. Provisional Application Ser. No. 60/893,745, filed Mar. 8, 2007, which is incorporated by reference.
Number | Date | Country | |
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60893745 | Mar 2007 | US |