Computer Cooling System And Method of Use

Abstract

A reliable, leak-tolerant liquid cooling system with a backup air-cooling system for computers is provided. The system may use a vacuum pump and a liquid pump and/or an air compressor in combination to provide negative fluid pressure so that liquid does not leak out of the system near electrical components. Alternatively, the system can use a single vacuum pump and a valve assembly to circulate coolant. The system distributes flow and pressure with a series of pressure regulating valves so that an array of computers can be serviced by a single cooling system. The system provides both air and liquid cooling so that if the liquid cooling system does not provide adequate cooling, the air cooling system will be automatically activated. The heat may be removed from the building efficiently with a cooling tower. A connector system is provided to automatically evacuate the liquid from the heat exchangers before they are disconnected. Various turbulators are also provided, as well as a system and method for optimizing the heat transfer characteristics of a heat exchanger to minimize total energy requirements.

1 . A turbulator for use in a liquid flow passageway of a coolant-containing heat exchanger that is adapted to transfer heat from an electrical component to the coolant, the passageway having a cross-sectional area, the turbulator comprising:
 a core that is substantially concentric to the passageway, the core having a cross-sectional area; and   a ridge structure connected to the core, the ridge structure radiating away from the core, and the ridge structure defining a flow path, wherein the flow path has a length more than twice the largest dimension of the passageway;   wherein the cross-sectional area of the core is at least 20% of the cross sectional area of the passageway.   
     
     
         2 . The turbulator of  claim 1 , wherein the ridge structure is adapted to allow leakage of coolant over the ridge structure sufficient to induce swirling of coolant, wherein the swirling of coolant is substantially perpendicular to flow path. 
     
     
         3 . The turbulator of  claim 1  wherein the flow path defines a shape selected from a group consisting a helix, a conical helix, a rectangular cross-section helix, a round cross-section helix, a rectangular cross-section single-entry helix, a rectangular cross-section double-entry helix, a round cross-section single-entry helix and a round cross-section double-entry helix. 
     
     
         4 . The turbulator of  claim 1  wherein the turbulator is adapted to direct a jet of coolant against a surface proximate the electrical component. 
     
     
         5 . The turbulator of  claim 1  wherein the turbulator and passageway define a second turbulence-inducing liquid flow path when the turbulator is placed in the passageway, the second turbulence-inducing liquid flow path being at least 25% shorter than the first flow path. 
     
     
         6 . The turbulator of  claim 5  wherein the second flow path causes swirling of the liquid in the first flow path. 
     
     
         7 . A liquid cooling system for cooling an electrical component, comprising:
 a coolant containing heat exchanger adapted to transfer heat from the electrical component to the liquid, the heat exchange comprising coolant flow passageway having a cross-sectional area;   a turbulator disposed of in the passageway comprising:
 a core that is substantially concentric to the passageway, the core having a cross-sectional area; and 
 a ridge structure connected to the core, the ridge structure radiating away from the core, and the ridge structure defining a flow path, wherein the flow path has a length more than twice the largest dimension of the passageway; 
 wherein the cross-sectional area of the core is at least 20% of the cross sectional area of the passageway. 
   
     
     
         8 . The system of  claim 7 , the heat exchanger further comprising a base plate thermally coupled to the component and a plurality of fins extending from the base plate. 
     
     
         9 . The system of  claim 7 , the heat exchanger further comprising a base plate thermally coupled to the device;
 a heat pipe thermally coupled to the base plate; and   the heat pipe thermally coupled to a plurality of fins.   
     
     
         10 . The system of  claim 7 , wherein the ridge structure is adapted to allow leakage of coolant over the ridge structure sufficient to induce swirling of coolant, wherein the swirling of coolant is substantially perpendicular to flow path. 
     
     
         11 . The system of  claim 7 , wherein the flow path defines a shape selected from a group consisting a helix, a conical helix, a rectangular cross-section helix, a round cross-section helix, a rectangular cross-section single-entry helix, a rectangular cross-section double-entry helix, a round cross-section single-entry helix and a round cross-section double-entry helix. 
     
     
         12 . The system of  claim 7 , further comprising:
 a vacuum pump adapted to propel the coolant through the passageway at less than ambient pressure.   
     
     
         13 . The system of  claim 12 , further comprising:
 a pressure sensor in fluid communication with the heat exchanger and adapted to take a pressure reading of the coolant; and   a controller connected to the pressure sensor adapted to signal an alert if the pressure reading is outside a normal operable range.   
     
     
         14 . The system of  claim 12 , further comprising:
 a pressure sensor in fluid communication with the heat exchanger and adapted to take a pressure reading of the coolant;   a valve in fluid communication with the heat exchanger; and   a controller connected to the pressure sensor and the valve, the controller adapted to open the valve to allow the flow of coolant into the heat exchanger when the pressure reading is within a normal operable range.   
     
     
         15 . The system of  claim 7 , further comprising:
 a vacuum pump adapted to remove the coolant from the heat exchanger when the heat exchanger is removed from the system.   
     
     
         16 . A method of minimizing the energy needed to cool heat-generating components inside a cabinet having a higher than ambient temperature, comprising the steps of:
 providing a heat exchanger comprising:
 a thermally conductive base adapted to thermally couple to the heat-generating components; 
 a plurality of thermally conductive fins extending outward from the base; and 
 one or more coolant pathways thermally coupled to the base and the fins; 
   balancing the thermal load of the heat generating components and the ambient air inside the cabinet by positioning the one or more coolant pathways relative to the base and the fins;   thermally coupling the heat exchanger to the heat generating components; and   providing a source of coolant to the one or more coolant pathways.   
     
     
         17 . The method of  claim 16 , further comprising the steps of:
 providing a fan and locating the fan so that it causes air to flow across one or more of the fins; and   balancing the thermal load of the heat generating components and the ambient air inside the cabinet by:
 positioning the one or more coolant pathways relative to the base and the fins in further view of the heat transfer effect of the fan; and 
 adjusting the speed of the fan. 
   
     
     
         18 . The method of  claim 16 , wherein the one or more pathways is a coolant flow passageway having a cross-sectional area;
 a turbulator disposed of in the passageway comprising:
 a core that is substantially concentric to the passageway, the core having a cross-sectional area; and 
 a ridge structure connected to the core, the ridge structure radiating away from the core, and the ridge structure defining a flow path, wherein the flow path has a length more than twice the largest dimension of the passageway; 
 wherein the cross-sectional area of the core is at least 20% of the cross sectional area of the passageway. 
   
     
     
         19 . The method of  claim 18 , wherein the ridge structure is adapted to allow leakage of coolant over the ridge structure sufficient to induce swirling of coolant, wherein the swirling of coolant is substantially perpendicular to flow path. 
     
     
         20 . The system of  claim 18 , wherein the flow path defines a shape selected from a group consisting a helix, a conical helix, a rectangular cross-section helix, a round cross-section helix, a rectangular cross-section single-entry helix, a rectangular cross-section double-entry helix, a round cross-section single-entry helix and a round cross-section double-entry helix.