BUSBAR ASSEMBLY FOR IMMERSION COOLING APPARATUS
20230369842 · 2023-11-16
Inventors
Cpc classification
H05K7/20818
ELECTRICITY
H05K7/1492
ELECTRICITY
International classification
Abstract
Embodiments of busbar assemblies for use in immersion cooling apparatuses are described herein. In one embodiment, a busbar assembly may include an insulator block and a busbar. The insulator block may include a first barrier having a first barrier height, a second barrier having a second barrier height, a channel located between the first barrier and the second barrier, and a slot formed in the channel. The busbar may be positioned in the slot and have an effective busbar height that is less than the first barrier height and less than the second barrier height. Other examples may be described and claimed.
Claims
1. A busbar assembly for an immersion cooling apparatus, the busbar assembly comprising: an insulator block comprising: a first barrier having a first barrier height; a second barrier having a second barrier height; a channel located between the first barrier and the second barrier; and a slot formed in the channel; and a busbar positioned in the slot, the busbar having an effective busbar height that is less than the first barrier height and less than the second barrier height.
2. The busbar assembly of claim 1, wherein the effective busbar height is measured from a bottom surface of the channel to a top surface of the busbar.
3. The busbar assembly of claim 1, wherein a first clearance gap is formed between the busbar and the first barrier, a second clearance gap is formed between the busbar and the second barrier, and the busbar has a busbar width, wherein at least one of the first clearance gap is greater than the busbar width or the second clearance gap is greater than the busbar width.
4. The busbar assembly of claim 1, wherein a first clearance gap is formed between the busbar and the first barrier, a second clearance gap is formed between the busbar and the second barrier, and a top surface of the busbar is recessed below a first support surface of the first barrier and a second support surface of the second barrier by a distance that is greater than at least one of the first clearance gap or the second clearance gap.
5. The busbar assembly of claim 1, wherein the insulator block comprises one or more dielectric materials selected from a group consisting of a phenolic material, a mylar material, a polyimide material, and an epoxy material.
6. The busbar assembly of claim 1, wherein the channel is one of a plurality of channels formed in the insulator block, the plurality of channels arranged in a parallel configuration, wherein the busbar is one of a plurality of busbars, each channel of the plurality of channels containing one of the plurality of busbars.
7. The busbar assembly of claim 6, wherein the plurality of busbars are adapted to transfer single-phase or three-phase electrical power.
8. The busbar assembly of claim 6, wherein the plurality of busbars comprise a first set of busbars configured to transfer three-phase electrical power and a second set of busbars configured to transfer three-phase electrical power, wherein the first set of busbars and the second set of busbars are arranged in a symmetrical configuration to allow an electrical device to be electrically connected to the plurality of busbars in at least one of a first orientation or a second orientation.
9. An immersion cooling apparatus comprising: an immersion tank comprising an upper portion, a lower portion, and a target liquid level therebetween, and further comprising an interior volume defined by a bottom portion and a plurality of side walls; and a busbar assembly positioned within the interior volume of the immersion tank and below the target liquid level, the busbar assembly comprising: an insulator block comprising: a first barrier having a first barrier height; a second barrier having a second barrier height; a channel located between the first barrier and the second barrier; and a slot formed in the channel; and a busbar positioned in the slot, the busbar having an effective busbar height that is less than the first barrier height and less than the second barrier height.
10. The immersion cooling apparatus of claim 9, wherein a first clearance gap is formed between the busbar and the first barrier, a second clearance gap is formed between the busbar and the second barrier, and the busbar has a busbar width, wherein at least one of the first clearance gap is greater than the busbar width or the second clearance gap is greater than the busbar width.
11. The immersion cooling apparatus of claim 9, wherein a first clearance gap is formed between the busbar and the first barrier, a second clearance gap is formed between the busbar and the second barrier, and a top surface of the busbar is recessed below a first support surface of the first barrier and a second support surface of the second barrier by a distance that is greater than at least one of the first clearance gap or the second clearance gap.
12. The immersion cooling apparatus of claim 9, wherein the channel is one of a plurality of channels formed in the insulator block, the plurality of channels arranged in a parallel configuration, wherein the busbar is one of a plurality of busbars, each channel of the plurality of channels containing one of the plurality of busbars.
13. The immersion cooling apparatus of claim 12, wherein the plurality of busbars are adapted to transfer single-phase or three-phase electrical power.
14. The immersion cooling apparatus of claim 12, wherein the plurality of busbars comprise a first set of busbars configured to transfer three-phase electrical power and a second set of busbars configured to transfer three-phase electrical power, wherein the first set of busbars and the second set of busbars are arranged in a symmetrical configuration to allow an electrical device to be electrically connected to the plurality of busbars in at least one of a first orientation or a second orientation.
15. The immersion cooling apparatus of claim 9, further comprising a pass-through connection assembly sealing an opening in the immersion tank, wherein the opening is located above the target liquid level.
16. The immersion cooling apparatus of claim 15, wherein the busbar is electrically connected to the pass-through connection assembly, and wherein the busbar extends from below the target liquid level to above the target liquid level.
17. A busbar assembly kit for an immersion cooling tank, the busbar assembly kit comprising: an insulator block comprising: a first barrier having a first barrier height; a second barrier having a second barrier height; a channel located between the first barrier and the second barrier; and a slot formed in the channel; and a busbar positionable in the slot, the busbar having an effective busbar height that is less than the first barrier height and less than the second barrier height when the busbar is positioned in the slot.
18. The busbar assembly kit of claim 17, wherein a first clearance gap is formed between the busbar and the first barrier, a second clearance gap is formed between the busbar and the second barrier, and the busbar has a busbar width, wherein at least one of the first clearance gap is greater than the busbar width or the second clearance gap is greater than the busbar width.
19. The busbar assembly kit of claim 17, wherein a first clearance gap is formed between the busbar and the first barrier, a second clearance gap is formed between the busbar and the second barrier, and a top surface of the busbar is recessed below a first support surface of the first barrier and a second support surface of the second barrier by a distance that is greater than at least one of the first clearance gap or the second clearance gap.
20. The busbar assembly kit of claim 17, wherein the insulator block comprises one or more dielectric materials selected from a group consisting of a phenolic material, a mylar material, a polyimide material, and an epoxy material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis is instead placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
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DETAILED DESCRIPTION
[0037] Two-phase immersion cooling systems employ phase change heat transfer, which enables them to cool electronic devices that produce high heat flux densities, such as high-performance computing servers containing one or more central processing units (CPUs) and graphics processing units (GPUs).
[0038] To avoid risk of fluid leakage from an immersion tank 201, in some embodiments, a busbar assembly 100 may penetrate the immersion tank 201 above a liquid level 605, as shown in
[0039] Unlike the prior art busbar assemblies shown in
[0040] The busbar assembly 100 may safely conceal one or more current carrying busbars 20 to prevent accidental short-circuiting or electrocution. The busbar assembly 100 may be suitable for single-phase immersion cooling or two-phase immersion cooling.
[0041] To enable two-phase immersion cooling without risk of dry-out, in some embodiments, the busbar assembly 100 may include channels 13 with ample gaps 30, 31 on each side of the busbars 20, as shown in
[0042] A two-phase immersion cooling apparatus 200 may include an immersion tank 201, as shown in
[0043] The immersion tank 201 may have an opening 220. The opening 220 may be located in a top portion of the immersion tank 201, as shown in
[0044] The immersion tank 201 may be partially filled with a liquid dielectric fluid 620, as shown in
[0045] The two-phase immersion cooling apparatus 200 may include a condenser (e.g., a cooling coil) 235, as shown in
[0046] The two-phase immersion cooling apparatus 200 may include a busbar assembly 100, as shown in
[0047] The busbar assembly 100 may include a pass-through connection assembly 40, as shown in
[0048] The connection block 41 may include a plurality of electrical connectors 45 that are structured and arranged to extend through the connection block 41 and the opening 240 and to electrically connect to a corresponding busbar 20 in the immersion tank 201. The electrical connector 45 can be, for example, a busbar portion, an electrical connection pin, or an electrical cable. Each electrical connector 45 may be configured to electrically connect an external power source to one of the plurality of busbars 20. As an example, the electrical connector 45 may include a terminal lug 48 that allows electrical power from a power outlet or power source to be supplied to the busbar 20.
[0049] During operation, waste heat generated by the electronic device(s) 800 is transferred from the electronic device(s) 800 to the liquid dielectric fluid 620 and a portion of liquid dielectric fluid 620 may heat, boil, and vaporize to form the dielectric vapor 615. The dielectric vapor 615 may rise through the dielectric liquid 620 into the headspace 206 of the immersion tank 201. To prevent loss of vapor 615 from the headspace 206, the pass-through connection assembly 40 may provide a fluid-tight seal against an exterior surface 222 and above the liquid level 605.
[0050] The pass-through connection assembly 40 may include a seal (e.g., a sealing device, such as a gasket, an O-ring, and the like) 42 between a bottom surface of the connection block 41 and an outer surface 222 of the immersion tank 201, as shown in
[0051] A bottom portion of the busbar assembly 100 may include an (e.g., chemically resistant) insulator block 10, as shown in
[0052] As shown in
[0053] The insulator block 10 may include a plurality of barriers 12, as shown in
[0054]
[0055] As shown in
[0056] Referring to
may be recessed below a top surface 18 of the barrier 12 by a distance (d.sub.recess). Recessing the busbar 20 below the top surface 18 may protect the busbar 20 and prevent accidental electrocution. For example, the top surface 18 may prevent a misplaced hand tool or electronic device chassis from accidentally contacting and short-circuiting the busbar 20. The top surfaces 18 of the barriers 12 also may support the electronic devices 800 and alleviate physical load from the busbars 20. For example, an electronic device 800 installed in the immersion tank 201 may rest against one or more top surfaces 18 and include an electrical connection that extends downward into the channel 13 and electrically connects to the base section 24 of the busbar 20.
[0057] In the example shown in
[0058] A first clearance gap 30 may be provided between the busbar 20 and a first adjacent barrier 12a. A second clearance gap 31 may be provided between the busbar 20 and a second adjacent barrier 12b. During two-phase cooling, the clearance gaps 30, 31 may allow vapor bubbles 616 to escape from the channel 13, as shown in
[0059] The first clearance gap 30 and the second clearance gap 31 may be approximately equal in size, resulting in the busbar 20 being substantially centered in the channel 13. The first clearance gap 30 may be greater (e.g., at least two times greater) than a busbar 20 width (w.sub.busbar). The second clearance gap 31 (w.sub.gap) may be greater (e.g., at least two times greater) than the busbar width.
[0060] The first barrier 12a may have a width (w.sub.barrier) greater (e.g., at least two times greater) than a width of the channel 13 (w.sub.channel). The second barrier 12b may have a width greater (e.g., at least two times greater) than the channel width (w.sub.channel).
[0061] The top surface 29 of the busbar 20 may be recessed below the first top surface 18a and/or may be recessed below the second top surface 18b. In some implementations, the top surface 29 of the busbar 20 may be recessed below both the first top surface 18a and the second top surface 18b at a distance that is at least equal to the width of the busbar. For example, the top surface 29 of the busbar 20 may be recessed below both the first top surface 18a and the second top surface 18b a distance at least equal to the width of the first clearance gap 30 or the second clearance gap 31.
[0062] The busbar assembly 100 may include one or more busbars 20. In one embodiment, the busbar assembly 100 may include any number of busbars 20 (e.g., a first busbar (L1), a second busbar (L2), and a third busbar (L3)) to support three-phase power transmission. The busbar assembly 100 may also include a protective earth busbar (PE) and/or a neutral busbar (N).
[0063] In some embodiments, the busbars 20 may be arranged in a symmetrical configuration, as shown in
[0064] More specifically,
[0065] In some embodiments, the busbar assembly 20 may be a kit of components that can be installed on an existing immersion tank 201. The kit may include the insulator block 10, one or more busbars 20, and the pass-through connection assembly 40.
[0066] As used herein, the term “fluid” may refer to a substance in gas form, liquid form, or a two-phase mixture of gas and liquid. The fluid may be capable of undergoing a phase change from liquid to vapor or vice versa. The liquid may form a free surface that is not created by a container in which it resides, while the gas may not.
[0067] As used herein, the term “vapor” may refer to a substance in a gas phase at a temperature lower than the substance's critical temperature. Therefore, the vapor may be condensed to a liquid by increasing pressure without reducing temperature.
[0068] As used herein, the term “two-phase” may refer to a vapor phase of a substance coexisting with a liquid phase of the substance. When this occurs, a gas partial pressure may be equal to a vapor pressure of the liquid.
[0069] As used herein, “target liquid level” may refer to a desired fluid level in an immersion tank. In one example, the target liquid level may be marked on an interior side wall of the immersion tank. Prior to use, the immersion tank may be filled with dielectric fluid up to the target liquid level.
[0070] A liquid dielectric fluid 620, such as a hydrofluorocarbon (HFC) or a hydrofluoroether (HFE), can be used as the fluid in the immersion cooling apparatus 200. Unlike water, dielectric fluids can be used in direct contact with electronic devices 800, such as microprocessors 801, memory modules, and power inverters, without risk of shorting electrical connections. Non-limiting examples of liquid dielectric fluids include 1,1,1,3,3-pentafluoropropane (known as R-245fa), hydrofluoroether (HFE), 1-methoxyheptafluoropropane (known as HFE-7000), methoxy-nonafluorobutane (known as HFE-7100). Hydrofluroethers, including HFE-7000, HFE-7100, HFE-7200, HFE-7300, HFE-7500, and HFE-7600, are commercially available as NOVEC Engineered Fluids from 3M Company headquartered in Mapleton, Minnesota. FC-40, FC-43, FC-72, FC-84, FC-770, FC-3283, and FC-3284 are commercially available as FLUOROINERT Electronic Liquids also from 3M Company.
[0071] The elements and method steps described herein can be used in any combination whether explicitly described or not. All combinations of method steps as described herein can be performed in any order, unless otherwise specified or clearly implied to the contrary by the context in which the referenced combination is made.
[0072] As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise.
[0073] The methods and compositions of the present invention can comprise, consist of, or consist essentially of the essential elements and limitations described herein, as well as any additional or optional steps, components, or limitations described herein or otherwise useful in the art.
[0074] It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the claims.
[0075] The foregoing description has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the claims to the embodiments disclosed. Other modifications and variations may be possible in view of the above teachings. The embodiments were chosen and described to explain the principles of the invention and its practical application to enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art.