Cooling systems and methods using single-phase fluid
A cooling system includes a heat exchanger having one or more rows of multiple flat tubes, louvered fins disposed between pairs of flat tubes, and special header tube connections to form a counter flow heat exchanger. Heat exchangers having multiple rows may be placed near or close to the server racks and may be in fluid communication with an outdoor heat exchanger having one or more rows. A single-phase fluid is pumped through a fluid circuit or loop, which includes the heat exchangers at the server racks and the outdoor heat exchanger. The single-phase fluid circuit including the heat exchangers at the IT racks may alternatively be in thermal communication with a water circuit that includes an outdoor fluid cooler. The flat tubes can be formed tubes with one or more channels, or extruded tubes with multiple channels. The heat exchangers include header tubes/connections, which facilitate easy fabrication and connection between rows and inlet/outlet, and lower the pressure drop.
1. A heat exchanger, comprising:
a first row including a first pair of header tubes and a first plurality of flat tubes coupled between the first pair of header tubes so that the first plurality of flat tubes is in fluid communication with the first pair of header tubes;
a second row including a second pair of header tubes and a second plurality of flat tubes coupled between the second pair of header tubes so that the second plurality of flat tubes is in fluid communication with the second pair of header tubes, a header tube of the first pair of header tubes integrally coupled to a header tube of the second pair of header tubes to enable fluid flow between the header tube of the first pair of header tubes of the first row and the header tube of the second pair of header tubes of the second row;
a plurality of fins disposed between each pair of the first and second plurality of flat tubes;
a plurality of header connectors integrally coupled to respective orifices in a first header tube of the first pair of header tubes on a first side of the first row;
a plurality of header connectors integrally coupled to respective orifices in a second header tube of the first pair of header tubes on a second side of the first row, wherein the first side of the first row is opposite the second side of the first row;
a plurality of header connectors integrally coupled to respective orifices in a first header tube of the second pair of header tubes on a first side of the second row; and
a plurality of header connectors integrally coupled to respective orifices in a second header tube of the second pair of header tubes on a second side of the second row, wherein the first side of the second row is opposite the second side of the second row,
wherein the plurality of header connectors integrally coupled to respective orifices in the second header tube of the first pair of header tubes on the second side of the first row is coupled to the plurality of header connectors integrally coupled to respective orifices in the first header tube of the second pair of header tubes on the first side of the second row, respectively.
2. The heat exchanger of claim 1 , wherein the first and second plurality of flat tubes are extruded or brazed aluminum tubes.
3. The heat exchanger of claim 1 , wherein each of the plurality of fins include a wave pattern in a direction of air flow.
4. The heat exchanger of claim 1 , wherein the plurality of fins are louvered fins.
5. The heat exchanger of claim 1 , further comprising:
a fluid inlet coupled to and in fluid communication with the first row;
a fluid outlet coupled to and in fluid communication with the second row; and
one or more fans configured to move hot air through the heat exchanger from the second row to the first row.
6. The heat exchanger of claim 1 , wherein the plurality of header connectors integrally coupled to respective orifices in the second header tube of the first pair of header tubes on the second side of the first row is coupled to the plurality of header connectors integrally coupled to respective orifices in the first header tube of the second pair of header tubes on the first side of the second row, respectively, through an O ring or a gasket and a plurality of fasteners.
7. The heat exchanger of claim 1 , further comprising a third row including a third pair of header tubes and a third plurality of flat tubes coupled between the third pair of header tubes so that the third plurality of flat tubes are in fluid communication with the third pair of header tubes, the other header tube of the second pair of header tubes integrally coupled to a header tube of the third pair of header tubes to enable fluid flow between the header tube of the second pair of header tubes and the header tube of the third pair of header tubes.
8. The heat exchanger of claim 1 , wherein each plurality of header connectors includes at least three header connectors.
9. The heat exchanger of claim 8 , wherein the at least three header connectors are disposed equidistant from each other.
10. A heat exchanger, comprising:
a first row including a first pair of header tubes and a first plurality of flat tubes coupled between the first pair of header tubes so that the first plurality of flat tubes is in fluid communication with the first pair of header tubes;
a second row including a second pair of header tubes and a second plurality of flat tubes coupled between the second pair of header tubes so that the second plurality of flat tubes is in fluid communication with the second pair of header tubes, a header tube of the first pair of header tubes integrally coupled to a header tube of the second pair of header tubes to enable fluid flow between the header tube of the first pair of header tubes of the first row and the header tube of the second pair of header tubes of the second row;
a plurality of fins disposed between each pair of the first and second plurality of flat tubes;
a plurality of header connectors integrally coupled to respective orifices in a first header tube of the first pair of header tubes on a first side of the first row;
a plurality of header connectors integrally coupled to respective orifices in a second header tube of the first pair of header tubes on a second side of the first row, wherein the first side of the first row is opposite the second side of the first row;
a plurality of header connectors integrally coupled to respective orifices in a first header tube of the second pair of header tubes on a first side of the second row; and
a plurality of header connectors integrally coupled to respective orifices in a second header tube of the second pair of header tubes on a second side of the second row, wherein the first side of the second row is opposite the second side of the second row,
wherein the plurality of header connectors integrally coupled to respective orifices in the second header tube of the first pair of header tubes on the second side of the first row is coupled to the plurality of header connectors integrally coupled to respective orifices in the first header tube of the second pair of header tubes on the first side of the second row, respectively, through an O ring or a gasket and a plurality of fasteners.