Rack-mounted equipment cooling

• US 6,668,565 B1
• Filed: 04/12/2002
• Issued: 12/30/2003
• Est. Priority Date: 04/12/2002
• Status: Active Grant

• Current Assignee: Schneider Electric IT Corporation (Schneider Electric SE)
• Original Assignee: American Power Conversion Corporation (Schneider Electric SE)
• Inventors: Johnson, Richard J., Anderson, Timothy J., Pfleging, Robert C., Kroupa, Daniel C.
• Primary Examiner(s): Tapolcai, William E.
• Assistant Examiner(s): Ali, Mohammad M.
• Application Number:
  US10/121,313
• Time in Patent Office: 627 Days
• Field of Search: 62/89, 622/55, 622/56, 622/592, 165/80.3, 361/695, 361/696, 361/697, 454/184
• US Class Current: 62/89
• CPC Class Codes: H05K 7/20581 Cabinets including a drawer for fans

Abstract

A gas distribution unit for use in a rack, that holds rack-mounted equipment that produces heat during operation, includes a housing defining a cavity, an exhaust port in a top wall of the housing, and at least one intake port configured to provide fluid communication between the cavity and a volume of gas external to the housing, the at least one intake port being at least partially laterally displaced relative to the exhaust port, the housing being configured to be disposed in and coupled to the rack and to direct gas from the cavity substantially directly upward through the exhaust port when coupled to the rack, and at least one fan coupled to and disposed within the housing and configured to draw gas through the at least one intake port, and to force the drawn-in gas out of the gas distribution unit through the exhaust port.

Claims

1. A gas distribution unit for use in a rack that holds rack-mounted equipment that produces heat during operation, the gas distribution unit comprising:

a housing defining a cavity, an exhaust port in a top wall of the housing, and at least one intake port configured to provide fluid communication between the cavity and a volume of gas external to the housing, the at least one intake port being at least partially laterally displaced relative to the exhaust port, the housing being configured to be disposed in and coupled to the rack and to direct gas from the cavity substantially directly upward through the exhaust port when coupled to the rack; and

at least one fan coupled to and disposed within the housing and configured to draw gas through the at least one intake port, and to force the drawn-in gas out of the gas distribution unit through the exhaust port.

2. The gas distribution unit of claim 1 wherein the exhaust port is defined adjacent a front edge of the housing.

3. The gas distribution unit of claim 2 wherein the housing has a curved transition between a bottom wall and a front side wall.

4. The gas distribution unit of claim 1 further comprising a plenum boot connected to the housing enclosing the at least one intake hole.

5. The gas distribution unit of claim 4 wherein the boot comprises a flexible material.

6. The gas distribution unit of claim 4 wherein an end of the boot that is displaced from the housing is configured to be attached to a surface defining a cool-gas port that provides access to a source of cool gas, the displaced end of the boot being configured to surround a perimeter of the cool-gas port.

7. The gas distribution unit of claim 1 wherein the housing is configured to be mounted into the rack such that a front wall of the housing is disposed adjacent to a front wall of the rack.

8. The gas distribution unit of claim 1 wherein the housing includes an interior wall that divides the cavity into a plurality of sub-cavities, and wherein the at least one fan includes at least one fan disposed within each sub-cavity.

9. The gas distribution unit of claim 8 further comprising multiple power inputs and a fail-over module electrically coupling the power inputs to the fans, the fail-over module being configured to disconnect a first of the power inputs from a first fan and connect a second of the power inputs to the first fan in response to a loss of power on the first power input.

10. The gas distribution unit of claim 8 wherein the at least one intake port includes at least one intake port for each sub-cavity, each intake port being associated with a corresponding fan, and wherein the fans each include a ring of fan blades configured and disposed to surround a perimeter of the corresponding intake port, each fan being configured to rotate the ring to draw gas through the corresponding intake port into an interior of the fan and to force the drawn-in gas radially outward through the ring.

11. The gas distribution unit of claim 8 wherein the interior wall that divides the cavity is S-shaped.

12. The gas distribution unit of claim 1 further comprising a filter apparatus coupled to the housing and configured to filter gas drawn into the at least one intake port by the at least one fan.

13. The gas distribution unit of claim 1 configured to be removably mounted to the rack.

14. The gas distribution unit of claim 13 wherein the housing is configured to at least one of rest on a support disposed in the rack and have tabs of the housing inserted into receptacles in rails of the rack.

15. The gas distribution unit of claim 1 wherein the housing is configured to primarily direct the gas from the cavity substantially directly upward through the exhaust port when coupled to the rack.

16. The gas distribution unit of claim 1 wherein at least one fan forces the drawn-in gas toward the exhaust port in a direction that is substantially perpendicular to a direction in which the air is drawn into the gas distribution unit.

17. A modular gas distribution unit for use in a rack that holds rack-mounted equipment that produces heat during operation, the rack-mounted equipment having corresponding fronts, the gas distribution unit comprising in combination:

a housing configured to be disposed in the rack;

a fan connected to the housing and configured to draw gas from a first region external to the housing and force the gas from the first region into a second region internal to the housing;

means for directing the gas forced into the second region upward adjacent the fronts of the rack-mounted equipment; and

means for guiding cool gas from a source of the cool gas to the first region, the means for guiding being configured to guide the cool gas for adjustable distances to accommodate different separations between the means for directing and the source of cool gas.

18. The gas distribution unit of claim 17 wherein the means for guiding includes a plenum comprising a flexible material.

19. The gas distribution unit of claim 17 wherein the means for directing includes an interior wall of the housing dividing a cavity, defined by the housing, into sub-cavities, the gas distribution unit further including at least another fan, with at least one fan disposed in each sub-cavity.

20. The gas distribution unit of claim 19 further comprising a redundant power distribution system coupled to provide power to the fans from multiple power sources, and to switch which power source provides power to a particular fan if the power source coupled to the particular fan fails.

21. The gas distribution unit of claim 19 further comprising a fan selector configured to control at least one of which combination of the fans will receive power and at which speed at least one of the fans will operate.

22. The modular gas distribution unit of claim 19 wherein the interior wall is constructed and arranged to provide a substantially similar mechanical impedance between each of the fans and the means for directing the gas.

23. The modular gas distribution unit of claim 22 wherein the means for directing the gas includes a curved portion between a bottom wall and a front side wall.

24. The gas distribution unit of claim 17 further comprising a filter apparatus coupled to the housing and configured and disposed to filter the cool gas.

25. The gas distribution unit of claim 17 configured to be removably mounted to the rack.

26. The modular gas disbribution unit of claim 17 wherein the housing defines at least one intake port at least partially laterally displaced relative to the means for directing the gas.