U.S. patent application number 13/622966 was filed with the patent office on 2014-03-20 for data center rack door.
The applicant listed for this patent is Greg Hilbert, David Knaggs, Paul A. Knight, Grayling A. Love, II. Invention is credited to Greg Hilbert, David Knaggs, Paul A. Knight, Grayling A. Love, II.
Application Number | 20140077672 13/622966 |
Document ID | / |
Family ID | 50273756 |
Filed Date | 2014-03-20 |
United States Patent
Application |
20140077672 |
Kind Code |
A1 |
Love, II; Grayling A. ; et
al. |
March 20, 2014 |
DATA CENTER RACK DOOR
Abstract
A data center rack door having a curved permeable member is
disposed vertically along a front-face of a data center rack. The
curved permeable member provides an increase in surface area that
provides for additional openings, increasing airflow through the
data center rack. The curved permeable member also provides an
increase in volume of space in the data center rack.
Inventors: |
Love, II; Grayling A.;
(Liberty Lake, WA) ; Knight; Paul A.; (Spokane,
WA) ; Knaggs; David; (Spokane, WA) ; Hilbert;
Greg; (Liberty Lake, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Love, II; Grayling A.
Knight; Paul A.
Knaggs; David
Hilbert; Greg |
Liberty Lake
Spokane
Spokane
Liberty Lake |
WA
WA
WA
WA |
US
US
US
US |
|
|
Family ID: |
50273756 |
Appl. No.: |
13/622966 |
Filed: |
September 19, 2012 |
Current U.S.
Class: |
312/236 ;
49/504 |
Current CPC
Class: |
H05K 5/0213 20130101;
H05K 5/0239 20130101; E06B 9/00 20130101; H05K 7/20736 20130101;
H05K 7/1488 20130101; E06B 9/01 20130101 |
Class at
Publication: |
312/236 ;
49/504 |
International
Class: |
H05K 5/02 20060101
H05K005/02; E06B 9/00 20060101 E06B009/00 |
Claims
1. A door for a data center rack, the door comprising: a vertical
frame member opposite another vertical frame member; a horizontal
frame member fixed between the vertical frame members, the
horizontal frame member comprising: a first end opposite a second
end; and a curved surface extending from the first end to the
second end, the horizontal frame member being fixed between the
vertical frame members and defining a curved front surface of the
door; and a permeable member interposed between the curved surface
of the horizontal frame member and the vertical frame members,
wherein the permeable member substantially conforms to the curved
surface of the horizontal frame member.
2. The door of claim 1, wherein the permeable member comprises a
mesh.
3. The door of claim 2, wherein the mesh is formed of a metal, a
plastic, or a composite.
4. The door of claim 2, wherein the mesh comprises mesh members
having a substantially round cross-sectional profile.
5. The door of claim 2, wherein the mesh includes precrimped wires,
intercrimped wires, welded wires, or flat top weave wires.
6. The door of claim 2, wherein the mesh includes mesh members
having a thickness of at least about 0.03 inches to at most about
0.1 inches.
7. The door of claim 2, wherein the mesh includes mesh members
separated by a distance of at least about 0.1 inches to at most
about 1.5 inches.
8. A data center rack comprising: a rack for removably receiving
data center equipment; and a door coupled to the rack to protect
the data center equipment, the door comprising: a frame comprising
a horizontal member having a curved surface, the curved surface
extending from a first end of the horizontal member to a second end
of the horizontal member, and defining a curved front surface of
the door, wherein the curved front surface extends away from the
rack when the door is arranged flush against the rack in a closed
position; and a permeable member interposed by first and second
vertical frame members of the frame and coplanar to the curved
front surface of the door.
9. The data center rack of claim 8, wherein the first vertical
frame member is fixed to the first end of the horizontal member,
and the second vertical frame member is fixed to the second end of
the horizontal member, each of the first and second vertical frame
members including a channel to receive an edge of the permeable
member.
10. The data center rack of claim 9, wherein the frame further
comprises an array of horizontal support ribs distributed
vertically between a top and bottom of the rack, and extending
between the first and second vertical frame members, the permeable
member coupled to and conforming with the horizontal support
ribs.
11. The data center rack of claim 10, wherein the frame further
comprises a front strip arranged vertically between the first and
second vertical frame members, and disposed adjacent to the
permeable member opposite to the array of horizontal support ribs,
and wherein the front strip and the array of horizontal support
ribs cooperate to retain the permeable member in the curved front
surface of the door.
12. A door for a data center rack, the door comprising: a vertical
frame member opposite another vertical frame member; a plurality of
horizontal frame members having a curved surface arranged between a
first end opposite a second end, wherein the first and second ends
of the plurality of horizontal frame members are fixed to the
vertical frame members; the plurality of horizontal frame members
are distributed along the vertical frame members; and the curved
surfaces of the plurality of horizontal frame members define a
curved front surface of the door; and a permeable member interposed
between the vertical frame members, and disposed adjacent to the
curved surfaces of the plurality of horizontal frame members,
wherein the permeable member conforms to the curved front surface
of the door.
13. The door of claim 12, further comprising a front strip arranged
vertically between the vertical frame members, and disposed
adjacent to the permeable member opposite to the curved surfaces of
the plurality of horizontal frame members, and wherein the front
strip and the plurality of horizontal frame members cooperate to
retain the permeable member in the curved front surface of the
door.
14. The door of claim 13, further comprising a bumper strip
removeably coupled to the front strip.
15. The door of claim 14, wherein the bumper strip comprises wood,
plastic, or rubber.
16. The door of claim 12, wherein the curved surface of the
plurality of horizontal frame members arranged between the first
and second ends of the plurality of horizontal frame members has a
radius of at least about 30 inches and at most about 50 inches.
17. The door of claim 12, further comprising a top cap fixed to a
top edge of the door and a bottom cap fixed to a bottom edge of the
door, wherein the top and bottom caps cover top and bottom voids
produced by the curved front surface of the door.
18. The door of claim 12, wherein the vertical frame members
include cooperating inner and outer components, the cooperating
inner and outer components having a channel arranged between the
inner and outer components to receive a portion of the permeable
member.
19. The door of claim 18, wherein the inner component comprises a
cross-sectional profile having a substantially asymmetrical S
shape, and the outer component comprising a cross-sectional profile
having a substantially asymmetrical U shape, a portion of the inner
component fixed to a portion of the outer component.
20. The door of claim 18, wherein the inner component comprises a
plurality of apertures arranged in the inner component to receive
the plurality of horizontal frame members.
Description
BACKGROUND
[0001] Thermal management of computing equipment and devices is
critical to their performance and reliability. The thermal
management equipment used to keep these computing equipment and
devices at a precise temperature consume large amounts of
power.
[0002] Thermal management devices and methods exist for managing
the temperature of a computing facility to provide an abundance of
air at the right temperature for the computing equipment and
devices housed within. For example, data center racks may be
arranged to intake cold air at the fronts of the data center racks
and exhaust hot air at the backs of the data center racks.
[0003] The effectiveness of these thermal management devices and
methods are dependent upon the ability to move air through the data
center racks. Doors exist that use sheet metal that is perforated
to provide the ability to move air through the data center racks.
However, the perforated sheet metal doors are limited to a maximum
percentage of open perforated space because of the sheet metal
punching process that forms the perforations. The limited
perforation size reduces the perforated sheet metal door's
efficiency to move air through the data center rack, thus consuming
more power and costing more money. Further, because the perforated
sheet metal doors are substantially flat, the perforated sheet
metal doors limit the space available for the data center racks to
which the perforated sheet metal doors are attached. Further, the
perforated sheet metal doors are often expensive to
manufacture.
[0004] Thus, there remains a need to develop new data center rack
doors that move air efficiently through data center racks.
SUMMARY
[0005] This Summary is provided to introduce concepts relating to
data center rack doors, which are further described below in the
Detailed Description. This Summary is not intended to identify
essential features of the claimed subject matter, nor is it
intended for use in determining the scope of the claimed subject
matter.
[0006] A data center rack door is provided that comprises a curved
permeable member that exhibits an increase in airflow through data
center racks, provides an increase in volume of data center racks,
and has as a lower cost of production. In some embodiments, such
data center rack doors may be configured to provide visibility of
the equipment housed in the data center racks, and provide front
and/or rear access to equipment housed in data center racks, while
providing security for the equipment housed in data center
racks.
[0007] In one example, a frame of the data center rack door may
include a horizontal frame member having a curved surface that may
define a curved front surface of the data center rack door. In
another example, a frame of the data center rack door may include a
plurality of horizontal frame members having a curved surface that
may define the curved front surface of the data center rack door.
In examples where the frame includes at least one horizontal frame
member having a curved surface, a permeable member may be
interposed between the curved surface of the horizontal frame
member and two vertical frame members. In examples where the frame
includes a plurality of horizontal frame members having a curved
surface, a permeable member may be interposed between the two
vertical frame members, and disposed adjacent to the curved
surfaces of the plurality of horizontal frame members. In any of
these examples, the permeable member may be substantially coplanar
to the curved front surface of the data center rack door.
[0008] In another example, the permeable member may comprise a
mesh. For example, the mesh may be a metal mesh, a plastic mesh, a
composite mesh, or the like suitable to provide increased airflow,
equipment visibility, security, and/or rigidity relative to
perforated sheet metal doors.
[0009] In another example, the frame of the data center rack door
may include a vertical frame member opposite another vertical frame
member. Here, the vertical frame members may include cooperating
inner and outer components, that when assembled together to form a
vertical frame member, have a channel arranged between the inner
and outer components. The channel may be for receiving a portion of
the permeable member.
[0010] In another example, a front strip may be arranged vertically
between the vertical frame members and disposed adjacent to the
permeable member. The front strip may be arranged to cooperate with
the horizontal frame members to retain the permeable member in the
curved front surface of the data center rack door.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The detailed description is described with reference to the
accompanying figures. The use of the same reference numbers in
different figures indicates similar or identical items.
[0012] FIG. 1 illustrates a data center rack door having a curved
permeable member, and disposed vertically along a front-face of a
data center rack.
[0013] FIG. 2 illustrates a back side perspective view of the data
center rack door illustrated in FIG. 1 apart from the data center
rack.
[0014] FIG. 3 illustrates a front side perspective view of the data
center rack door illustrated in FIG. 1 apart from the data center
rack.
[0015] FIG. 4 illustrates a detail section view of a vertical frame
member illustrated in FIG. 3.
[0016] FIG. 5 is a flow diagram illustrating an example process of
manufacturing a data center rack door.
DETAILED DESCRIPTION
Overview
[0017] As discussed above, existing data center rack doors fail to
adequately provide airflow through data center racks. For example,
existing doors fail to adequately move air through data center
racks that are inexpensive to fabricate, and that provide an
increased volume of useable space in the data center racks.
[0018] This disclosure is directed to data center rack doors having
a curved permeable member disposed vertically along front-faces
and/or back-faces of data center racks. The curved permeable member
thereby increases a surface area as compared to a flat permeable
front member. The increased surface area provides for additional
openings in the increased surface area. Thus, the curved permeable
member increases a percentage of total area of open space per total
area of closed space of a total area of the curved permeable
member. The increase in open space thereby reduces an amount of
energy needed to maintain a desired pressure differential across
the permeable front member to provide an efficient airflow for the
equipment housed in the data center racks.
[0019] Traditionally, data center rack doors have been made to be
substantially flat. Because these traditional data center rack
doors are flat, they do not provide any additional space in a data
center rack. As such, a user must manage equipment housed in data
center racks in restricted space. For example, a user may need to
manage cables routed in a data center rack in front and/or in back
of equipment housed in the data center racks. The space in front
and/or in back of the equipment housed in the data center rack may
be restricted or limited by the data center rack door, when the
door is in a closed position. In some instances, the data center
rack space may be restricted or limited to the point where a user
may not be able to route cables or manage the equipment housed in
the data center rack. Thus, data center rack space is highly
valued. Accordingly, this disclosure describes data center rack
doors having curved permeable members that provide increased volume
of space in the data center rack when in a closed position, and
therefore provide operational personnel the improved ability to
manage equipment housed in data center racks while simultaneously
keeping the computing equipment and devices performing
optimally.
[0020] To achieve the lower cost of production, in one example this
application describes a curved permeable member that is formed of a
mesh. The mesh being cheaper to fabricate than fabricating
perforated sheet metal. In addition to being cheaper to fabricate,
the installation of the mesh requires minimal tooling making
assembly less expensive and less time consuming.
[0021] The mesh may be of any suitable mesh capable of providing
sufficient rigidity, increased airflow, equipment visibility,
and/or security. For example, the mesh may be a metal mesh (e.g.,
steel mesh, aluminum mesh, iron mesh, etc.) a plastic mesh (e.g.,
polystyrene mesh, polyethylene mesh, polyvinyl chloride mesh,
polyamide mesh, etc.), a composite mesh (e.g., carbon fiber mesh,
fiberglass mesh, etc.) or the like suitable to provide sufficient
rigidity, increased airflow, equipment visibility, and/or
security.
[0022] In an example embodiment where the mesh comprises a metal
mesh, the mesh may include precrimped wires, intercrimped wires,
welded wires, flat top weave wires, or any other wire type mesh. In
some examples, wire mesh may have openings of at least about 0.25
inch voids to at most about 1 inch voids. However, in other
examples, the wire mesh may have openings smaller than 0.25 inch
voids and/or larger than 1 inch voids. In such examples, the wire
mesh may have openings of at least about 0.1 inch voids to at most
about 2 inch voids. The wire mesh may have a substantially round,
square, half-round, oval, triangle, or other any other
cross-sectional profile. For example, the wire mesh may have a
diameter or thickness of at least about 0.03 inches to at most
about 0.125 inches. Because the wire mesh may be formed to include
the openings and wire thickness specified above, the wire mesh
provides for increased airflow, equipment visibility, security, and
rigidity. For example, where the wire mesh has a diameter of about
0.125 inches and the voids in the wire mesh are about 1 inch, the
open space is about 64% of the total area of the wire mesh, while
the closed space is about 36% of the total area of the wire
mesh.
[0023] In one example, the permeable member may be interposed
between a curved surface of a horizontal frame member and two
vertical frame members of a data center rack door. The curved
surface and the two vertical frame members may fix the permeable
member in a curvilinear shape vertically along the data center rack
door. For example, the horizontal frame member may include a curved
surface extending from a first end to a second end of the
horizontal frame member that, when fixed between the two vertical
frame members, defines a curved front surface of the data center
rack door. A portion (e.g., edges) of the permeable member may be
retained or housed by one or both of the two vertical frame
members. The curved surface of the horizontal frame member may
displace or deform the permeable member into a substantially
similar curvilinear shape as the curved surface. Thus, the
permeable member may be displaced or deformed to be fixed coplanar
to the curved front surface of the data center rack door. The
curved surface extending from the first end to the second end of
the horizontal frame member may have a radius of at least about 30
inches and at most about 50 inches.
[0024] In another example, the permeable member may be interposed
between a plurality of horizontal frame members having a curved
surface arranged between a first end opposite a second end of the
horizontal frame members. The curved surface may be substantially
the same for each horizontal frame member, and the plurality of
horizontal frame members may be distributed evenly from a top of
the data center rack door to a bottom of the data center rack door.
However, the horizontal frame members disposed at the top and/or
bottom of the data center rack door may include different width
than the plurality of horizontal frame members evenly distributed
between the top and bottom of the data center rack door. For
example, the horizontal frame members disposed at the top and/or
bottom of the data center rack door may have a curved surface
having a width of about 2 inches, while the plurality of horizontal
frame members evenly distributed between the top and bottom of the
data center rack door may have a curved surface having a width of
about 1/8 inch.
[0025] The plurality of horizontal frame members evenly distributed
between the horizontal frame members disposed at the top and/or
bottom of the data center rack door may be defined as an array of
horizontal support ribs. For example, the plurality of horizontal
frame members evenly distributed between the top and bottom of the
data center rack door having a curved surface area smaller than a
curved surface area of the horizontal frame members disposed at the
top and/or bottom of the data center rack door may be an array of
horizontal support ribs. The horizontal support ribs may be
distributed vertically between the two vertical frame members and
disposed adjacent to the permeable member. The plurality of
horizontal support ribs may connect to the two vertical frame
members via slots arranged in the vertical frame members. The
plurality of horizontal support ribs may be substantially crescent
shaped to further define the curved front surface of the data
center rack door. For example, the horizontal support ribs may
include a curved surface having substantially the same radius as
the curved surface of the horizontal frame members disposed at the
top and/or bottom of the data center rack door. Thus, the evenly
distributed horizontal support ribs may further define the curved
surface between the top of the data center rack door and the bottom
of the data center rack door.
[0026] In another example, the permeable member may be retained or
fixed in the curved front surface of the data center rack door by a
front strip. The front strip may be arranged vertically between the
two vertical frame members, and disposed adjacent to the permeable
member opposite to the array of horizontal support ribs. The front
strip and the array of horizontal support ribs may cooperate to
retain the permeable member in the curved front surface of the data
center rack door. For example, one or more of the array of
horizontal support ribs may include tabs arranged to couple with
cooperating fasteners disposed on the front strip, or vice versa.
Thus, when the front strip is coupled to the array of horizontal
support ribs through the permeable member, the front strip on the
front/outside and the array of horizontal support ribs on the
back/inside cooperate to retain (e.g., clamp or sandwich) the
permeable member in the curved front surface of the data center
rack door.
[0027] Additionally or alternatively, a portion of the permeable
member may be received by a channel arranged in one or both of the
two vertical frame members. For example, the vertical frame members
may include cooperating inner and outer components. The inner
component may comprises a cross-sectional profile having a
substantially asymmetrical S shape. The outer component may
comprise a cross-sectional profile having a substantially
asymmetrical U shape. A portion of the inner component may be fixed
to a portion of the outer component, and a channel may be arranged
between the inner and outer components to receive the portion of
the permeable member. The channels may provide for sliding or
displacing the permeable member along the two vertical members to
install the permeable member in the data center rack door. For
example, the permeable member may be slid or displaced down the
vertical members, via the channels until a portion (e.g., a bottom
horizontal portion) of the permeable member is flush with a portion
(e.g., a bottom) of the horizontal frame member disposed at a
bottom of the data center rack door, and/or flush with a portion
(e.g., a top) of the horizontal frame member disposed at a top of
the data center rack door. Further, one side of the permeable
member may be slid or displaced down a vertical member, and the
other side of the permeable member may be inserted into the other
vertical member by curling or deforming the permeable member to
insert the other side of the permeable member into the other
vertical member.
[0028] Because these data center rack doors have a curved permeable
member disposed vertically along the data center rack door, these
data center rack doors provide an increased percentage of open
space per closed space. By providing an increased percentage of
open space, the data center rack door provides a more efficient air
flow through the data center racks. Further, because these data
center rack doors have a curved permeable member disposed
vertically along the data center rack door, these data center rack
doors provide an increased volume of space in the data center rack.
By providing an increased volume of space in the data center rack,
the data center rack door provides an improved ability to manage
equipment housed in the data center racks.
[0029] While the illustrated embodiments show vertical frame
members, horizontal frame members, horizontal ribs, and/or a front
strip as being formed of a metal (e.g., a steel, an aluminum, an
iron, etc.) and coated with a finish (e.g., a powder coat finish,
an electroplate finish, a galvanized finish, a paint finish, etc.),
other materials and/or finishes are contemplated. For example, the
vertical frame members, horizontal frame members, horizontal ribs,
and/or front strip may be formed of plastic, composite, or
wood.
[0030] Further, while the illustrated embodiments show a door for
coupling to a data center rack having dimensions of about 73 inches
(42 rack units) in height, by about 24 inches, or about 28 inches,
in width, other dimensions are contemplated. For example, the door
may be configured to be coupled to any sized data center rack. For
example, the door may be configured to be coupled to a rack having
dimensions of about 38 inches (22 rack units) in height. Further,
while the illustrated embodiments show a door for coupling to a
front-face of the data center rack, the door may be for coupling to
either the front-face and/or a back-face of the data center
rack.
[0031] The term "data center" is used to describe a server room, a
central office, a remote site, or any other facility housing
computing equipment and/or other electronics.
[0032] The term "operational personnel" is used to describe
personnel tasked with a computing facility's operation and
maintenance.
[0033] The term "rack" is used to describe chassis or cabinets that
provide for housing computing equipment and/or devices.
Example Data Center Rack Door
[0034] FIG. 1 illustrates a data center rack door 102 having a
curved permeable member 104 disposed vertically along a front-face
106 of a data center rack 108. The curved permeable member 104 may
comprise a mesh. For example, the curved permeable member 104 may
comprises a metal mesh, a plastic mesh, a composite mesh, or any
other suitable mesh that provides sufficient rigidity, increased
airflow, equipment visibility, and/or security. In one example,
detail view 110 illustrates a metal mesh 112 having mesh members
114 that are pre-crimped. The mesh members 114 may be separated by
a distance 116. The separated mesh members 114 may define openings
118 arranged in the metal mesh 112. The distance 116 separating the
mesh members 114, and defining the openings 118, may be any
suitable dimensions to provide efficient air flow, such as those
examples described above.
[0035] Detail view 110 also illustrates a section line A-A. Section
line A-A is illustrated as being taken across a mesh member 114.
Detail view 120 illustrates a section view of the mesh member 114
taken along section line A-A. Detail view 120 illustrates that the
mesh members 114 may comprise a substantially round cross-sectional
profile 122. While the detail view 120 illustrates a mesh member
114 comprising a substantially round cross-sectional profile 122,
other profiles are contemplated. For example, the mesh members 114
may comprise a substantially oval cross-sectional profile, a
substantially polygonal cross-sectional profile (e.g., rectangular,
hexagonal, etc.), or any other profile suitable to provide for
increased airflow, equipment visibility, security, and/or
sufficient rigidity.
[0036] In examples where the mesh members 114 comprise a
substantially round cross-sectional profile 122, airflow around the
mesh members 114 may be more efficient than airflow around a
rectangular cross-sectional profile. For example, the airflow
around the substantially round cross-sectional profile 122 may be
substantially more laminar as compared to airflow around a
rectangular cross-sectional profile presented by punched sheet
metal. Further, because the mesh members 114 may comprise a
substantially round cross-sectional profile 122, the mesh members
114 may be arranged to have a higher percentage of openings 118
than a percentage of openings punched in sheet metal. For example,
because the mesh members 114 may be arranged to have openings 118
having a distance separating the mesh members 114, the mesh members
may provide for a higher percentage of openings 118 than punched
sheet metal. This is because the perforated sheet metal may be
limited to a maximum percentage of openings by a restricted
proximity that the openings can be punched adjacent to each other
without structurally compromising or causing deformations in the
sheet metal. For example, the perforated sheet metal may be limited
to a minimum material width (i.e., "bar width") disposed between
two perforations. The minimum material width disposed between two
perforations may be about three times the material thickness of the
material (e.g., steel or other high-strength alloys).
[0037] The data center rack door 102 may include a vertical frame
member 126(A) opposite another vertical frame member 126(B). The
vertical frame members 126(A) and 126(B) may define side portions
of the frame of the data center rack door 102. The vertical frame
member 126(A) may include a handle and lock assembly 128 arranged
in a mortise formed in the permeable member 104. For example,
vertical frame member 126(A) may include additional material having
a width to provide for including an opening in the frame member
126(A) to accommodate the handle and lock assembly 128. The mortise
may be formed in the permeable member 104 to align with the opening
and receive a portion of the handle and lock assembly 128. The
vertical frame member 126(B) may include one or more hinge
assemblies 130 to pivotably couple the data center rack door 102 to
the data center rack 108.
[0038] The data center rack door 102 may include a plurality of
horizontal frame members 132(1), 132(2), 132(3), 132(4), 132(5),
132(6), 132(7), 132(8), 132(9), and 132(N) distributed vertically
between the vertical frame members 126(A) and 126(B). The plurality
of horizontal frame members 132(1)-132(N) may be substantially
evenly spaced between a top 134 and a bottom 136 of the data center
rack 108. The plurality of horizontal frame members 132(1)-132(N)
may define a curved front surface 138 of the data center rack door
102. For example, and as discussed in more detail below with regard
to FIG. 2 and FIG. 3, the plurality of horizontal frame members
132(1)-132(N) may have curved surfaces having substantially the
same radius (e.g., a radius of about 42 inches in this example).
Thus, when the curved permeable member 104 is installed in the data
center rack door 102, the plurality of horizontal frame members
132(1)-132(N) may be arranged to be disposed adjacent to the curved
permeable member 104 to define the curved front surface 138 of the
data center rack door 102.
[0039] The horizontal frame member 132(1) arranged proximate to the
bottom 136 of the data center rack 108 and the horizontal frame
member 132(N) arranged proximate to the top 134 of the data center
rack 108 may define top and bottom portions of the frame of the
data center rack door 102. The two horizontal frame members 132(1)
and 132(N) may have a curved surface area larger than a curved
surface area of the horizontal frame members 132(2)-132(9). For
example, the horizontal frame members 132(2)-132(9) may be an array
of horizontal support ribs having a thin curved surface area (e.g.,
a width of about 1/8 inch) opposed from the horizontal frame
members 132(1) and 132(N) that may have a wide curved surface area
(e.g., a width of about 2 inches). This is because the two
horizontal members 132(1) and 132(N) arranged proximate to the
bottom 136 and top 134 of the data center rack 108 may define or
establish the curved front surface 138, while the horizontal frame
members 132(2)-132(9) may provide for further defining or further
establishing the curved front surface 138 between the two
horizontal members 132(1) and 132(N). For example, the two
horizontal frame members 132(1) and 132(N) may deform the permeable
member 104 proximate to the top and bottom portions of the data
center rack door 102, while the horizontal frame members
132(2)-132(9) may augment the deforming of the permeable member 104
between the two horizontal members 132(1) and 132(N).
[0040] The curved permeable member 104 may have a length 140 about
equal to a length 142 of the vertical frame members 126(A) and/or
126(B). The vertical frame members 126(A) and/or 126(B) may have a
length about equal to a vertical height 148 of the data center rack
108. For example, the vertical height 148 of the data center rack
108 may be any standard rack height. For example, the vertical
height 148 may be about 39 inches (22 rack units) to 84 inches (48
rack units) or more in height. The curved permeable member 104 may
have a width 144 less than a length 146 of the plurality of
horizontal frame members 132(1)-132(N). The length 146 of the
plurality of horizontal frame members 132(1)-132(N) may be about
the same as a width 150 of the data center rack 108 (e.g., 24 inch
or about 28 inch). The curved permeable member 104 may be
interposed between the curved surface(s) of one or more of the
horizontal frame members 132(1)-132(N) and the vertical frame
members 126(A) and/or 126(B). Because the curved permeable member
104 may be interposed between the curved surface(s) of one or more
of the horizontal frame members 132(1)-132(N) and the vertical
frame members 126(A) and 126(B), the permeable member 104 may be
fixed substantially coplanar to the curved front surface 138.
[0041] The data center rack door 102 may include a front strip 152
arranged vertically between the vertical frame members 126(A) and
126(B), and disposed adjacent to the curved permeable member 104
opposite to the horizontal frame members 132(1)-132(N). The front
strip 152 and the horizontal frame members 132(1)-132(N) may
cooperate to retain the curved permeable member 104 in the curved
front surface 138 of the data center rack door 102.
[0042] With the data center rack door 102 having a curved permeable
member 104 disposed vertically along a front-face 106 of a data
center rack 108, the curved data center rack door 102 provide an
increased percentage of open space per closed space, and moves air
more efficiently through the data center rack 108 as compared to a
flat perforated metal door. In one example, a wire mesh having a
wire diameter of about 0.0625 inches would have about 80% total
open space versus a perforated door having a material thickness of
about 0.0625 inches would have about 53% total open space, or about
30% less open space than the wire mesh. This is because perforated
sheet metal may be limited to a minimum material width (i.e., "bar
width") disposed between two perforations. For example, the
perforations may need to be separated by a distance (i.e., "bar
width") at least about three times the material thickness of the
material, reducing the percentage of open space per closed space.
In addition, with the data center rack door 102 having a curved
permeable member 104 disposed vertically along a front-face 106 of
a data center rack 108, the curved data center rack door 102
provides an increased volume of space in the data center rack 108.
For example, the curved data center rack door 102 may provide at
least about an additional 2 inches of space from the front-face 106
of the data center rack 108 to the curved permeable member 104 of
the data center rack door 102. Further, with the data center rack
door 102 having a curved permeable member 104 that includes mesh
members 114 that may be separated by a distance 116 of at least
about 0.25 inches to at most about 1 inch, the data center rack
door 102 provides visibility of the equipment housed in the data
center rack 108, while providing security for the equipment housed
in data center rack 108.
[0043] FIG. 2 illustrates a back side view of the data center rack
door 102 illustrated in FIG. 1. FIG. 2 illustrates the plurality of
horizontal frame members 132(1), 132(2), 132(3), and 132(4) may be
disposed adjacent to the curved permeable member 104 defining the
curved front surface 138 of the data center rack door 102. The
horizontal frame member 132(1) may include a first end 202 opposite
a second end 204, and a curved surface 206 extending from the first
end 202 to the second end 204. The curved horizontal frame member
132(1) may fixed between the vertical frame members 126(A) and
126(B), defining the curved front surface 138 of the data center
rack door 102. For example, the curved permeable member 104 may be
interposed between the curved surface 206 of the horizontal frame
member 132(1) and the vertical frame members 126(A) and 126(B), and
fixed substantially coplanar to the curved front surface 138. For
example, the vertical frame members 126(A) and 126(B) may include
channels to receive respective portions 208(A) and 208(B) (e.g.,
vertical edges) of the permeable member 104, while the curved
surface 206 deforms or bends the permeable member 104 into a
substantially similar radius as the radius of the curved surface
206. Thus, the curved permeable member 104 interposed between the
curved surface 206 of the horizontal frame member 132(1) and the
vertical frame members 126(A) and 126(B) may be fixed substantially
coplanar to the curved front surface 138 defined by the curved
surface 206 of the horizontal frame member 132(1).
[0044] The curved surface 206 may have a radius 210 of at least
about 30 inches and at most about 50 inches. The curved surface 206
may have a width 212 of about 2 inches to be disposed adjacent to
the permeable member 104. The horizontal frame members
132(2)-132(9) may have a curved surface 214 having substantially
the same radius 210 as the curved surface 206. The curved surface
214 may extend between a first end 216 opposite a second end 218.
The curved horizontal frame members 132(2)-132(9) may be fixed
between the vertical frame members 126(A) and 126(B) to further
define the curved front surface 138 between the horizontal frame
members 132(1) and 132(N) of the data center rack door 102. For
example, the curved permeable member 104 may be further interposed
between the curved surfaces 214 of the horizontal frame members
132(2)-132(9) and the vertical frame members 126(A) and 126(B) in
the space between the horizontal frame members 132(1) and 132(N).
The curved surfaces 214 may have a width 220 of about 1/8 inch to
be disposed adjacent to the permeable member 104.
[0045] The curved horizontal frame members 132(2)-132(9) may
include fastening mechanisms 222 to provide for retaining the
permeable member 104 in the curved front surface 138 of the data
center rack door 102. For example, the curved horizontal frame
members 132(2)-132(9) may include tabs that provide for coupling
the front strip 152 to the curved horizontal frame members
132(2)-132(9) through the permeable member 104. The coupled front
strip 152 and curved horizontal frame members 132(2)-132(9) may
retain the permeable member 104 in the curved front surface 138 of
the data center rack door 102. The first and second ends 216 and
218 of the curved horizontal frame members 132(2)-132(9) may be
received by apertures 224 (e.g., slots, notches, indentations,
grooves, pockets, etc.) formed in the vertical frame members 126(A)
and 126(B). Further, the first and second ends 216 and 218 of the
curved horizontal frame member 132(2)-132(9) may be welded to the
vertical frame members 126(A) and 126(B).
[0046] Because the horizontal frame members 132(1)-132(N) may
include curved surfaces 206 and/or 214 having a radius 210 of at
least about 30 inches and at most about 50 inches, the curved
permeable member 104 may be deformed or curved out from the
vertical frame members 126(A) and 126(B) by a distance 226 or gap
of at least about 2 inches. Thus, when the data center rack door
102 is coupled to the data center rack 108, the distance 226
provided by the curved permeable member 104 may increase a space of
the data center rack 108 as compared to a flat perforated sheet
metal door. For example, because the curved permeable member 104
curves out from the data center rack 108, when in the closed
position, the distance 226 may provide an increase in space of the
data center rack 108 by the distance 226.
[0047] The data center rack door 102 may include a bottom cap 228
fixed to a bottom edge 230 of the data center rack door 102. The
bottom cap 228 may be placed over the bottom edge 230 to provide
for covering a portion 232 (e.g., a horizontal edge) of the
permeable member 104. The bottom cap may also cover the distance
226 or gap provided by the curved permeable member 104.
[0048] FIG. 3 illustrates a front side view of the data center rack
door 102 illustrated in FIG. 1. As discussed above, the plurality
of horizontal frame members 132(1)-132(N) may be disposed adjacent
to the curved permeable member 104 defining the curved front
surface 138 of the data center rack door 102. The curved permeable
member 104 may be interposed between the curved surface 206 of the
horizontal frame member 132(N) and the vertical frame members
126(A) and 126(B), and fixed substantially coplanar to the curved
front surface 138.
[0049] The data center rack door 102 may include a top cap 302
fixed to a top edge 304 of the data center rack door 102. The top
cap 302 may be placed over the top edge 304 to provide for covering
a portion 306 (e.g., a horizontal edge) of the permeable member
104. The top cap 302 may also cover the distance 226 or gap
provided by the curved permeable member 104. The top cap 302 may
include a surface 308 that provides a space for decorative designs,
labeling, and branding. For example, the top cap 302 may have
diamond tread design impressed into the surface 308, and/or two
colored chevrons on either side of a trapezoidal label arranged
proximate to a middle portion of the surface 308 as shown in FIG.
1.
[0050] The data center rack door 102 may include a bumper strip
310. The bumper strip 310 may be removeably coupled to the front
strip 152. For example, the front strip 152 may include a
v-channel, a slot, a groove, etc. to provide for receiving a
cooperating portion of the bumper strip 310. The bumper strip 310
may be formed of semi-flexible material. For example, the bumper
strip 310 may be formed of polyethylene, polystyrene, polyvinyl
chloride, polyamide, or any other plastic that is deformable.
Further, the bumper strip 310 may be formed of other materials. For
example, the bumper strip may be formed of rubber, wood,
fiberglass, carbon fiber, etc.
[0051] In some embodiments, the bumper strip 310 may include a
thermochromic indicator. For example, the bumper strip 310 may
include a thermochromic indicator this is a strip of thermochromic
ink, an array of individual thermochromic marks, thermochromic
paint applied to the bumper strip 310, thermochromic plastic
fastened to the bumper strip 310, thermochromic labels fastened to
the bumper strip 310, or the like, capable of being seen from a
distance. Because the thermochromic indicator is visible from a
distance it provides a visual indicator of air temperatures along
substantially the entire vertical height 148 of the data center
rack 108. By providing a real-time visual of air temperatures along
substantially the entire vertical height 148 of the data center
rack 108, the thermochromic indicator in turn provides operational
personnel with the ability to see hot spots, airflow mixing, and
inadequate airflow.
[0052] The horizontal frame members 132(2)-132(9) may have a depth
312 of about 1.5 inches. The depth 312 of the frame members
132(2)-132(9) may provide a high strength/rigidity to the door as
compared to smaller frame members. FIG. 3 also illustrates a
section line B-B. Section line B-B is illustrated as being taken
across vertical frame member 126(A).
[0053] FIG. 4 illustrates a section view of the vertical frame
member 126(A) taken along section line B-B, illustrated in FIG. 3.
FIG. 4 illustrates that the vertical frame members 126(A) and
126(B) may include a channel 402 to receive an edge (i.e., portion
208(A) or 208(B)) of the permeable member 104. The vertical frame
members 126(A) and 126(B) may include an inner component 404 and an
outer component 406. In one example, detail view 408 illustrates
the inner component 404 may comprise a cross-sectional profile 410
having a substantially asymmetrical S shape. The asymmetrical S
shape may include a flange 412 wider than another flange 414. The
inner component 404 may include the apertures 224 (e.g., slots,
notches, indentations, grooves, pockets, etc.) formed in the inner
component 404.
[0054] In another example, detail view 416 illustrates the outer
component 406 may comprise a cross-sectional profile 418 having a
substantially asymmetrical U shape. The asymmetrical U shape may
include a flange 420 wider than another flange 422.
[0055] The outer component 406 may be fixed around the inner
component 404. For example, the other flange 422 of the outer
component 406 may be welded to a portion of the flange 412 of the
inner component 404. After the outer component 406 and inner
component 404 are assembled together, the flange 420 of the outer
component 406 may be disposed above the other flange 414 of the
inner component 404, and define the channel 402.
[0056] The flange 420 may be arranged to be substantially parallel
to the other flange 414. The flanges 420 and 414 may be separated
by a distance 424 of about the same as a thickness of the permeable
member 104. For example, the permeable member may be at least about
0.03 inches thick to at most about 0.3 inches thick, and the
channel 402 may have a distance 424 slightly larger than at least
about 0.03 inches to at most about 0.3 inches to receive and clamp
the permeable member 104. For example, the distance 424 may be at
least about 0.06 inches to at most about 0.8 inches.
[0057] The channel 402 may provide for displacing or sliding the
permeable member 104 into the front of the data center rack door
102. For example, the permeable member 104 may be displaced or slid
down substantially the entire length 142 of the vertical frame
members 126(A) and 126(B) until the portion 232 (i.e., bottom
horizontal edge of the permeable member 104) is flush with a bottom
edge of the bottom horizontal frame member 132(1), and the portion
306 (i.e., top horizontal edge of the permeable member 104) is
flush with a top edge of the top horizontal frame member
132(N).
Example Method of Manufacturing Data Center Rack Doors
[0058] FIG. 5 illustrates an example process 500 of manufacturing a
data center rack door (e.g., data center rack door 102) having a
curved permeable member (e.g., curved permeable member 104). By way
of example and not limitation, this process may be performed at a
manufacturing facility, a plant, a foundry, a factory, or the like.
Some or all operations may be performed onsite in a customer
facility.
[0059] Process 500 includes operation 502, which represents
assembling vertical frame members (e.g., vertical frame members
126(A) and 126(B)). For example, an outer component (e.g., outer
component 406) may be fixed (e.g., welded) to an inner component
(e.g., inner component 404). The assembled vertical frame members
may include a channel (e.g., channel 402) to receive vertical edges
(e.g., portions 208(A) and 208(B)) of the permeable member.
[0060] Operation 502 may be followed by operation 504, which
represents fixing horizontal frame members (e.g., horizontal frame
members 132(1) and 132(N)) to the vertical frame members. For
example, the horizontal frame members may be fixed to a top and
bottom of the data center rack door.
[0061] Process 500 may include operation 506, which represents
installing an array of horizontal support ribs (e.g., horizontal
frame members 132(2)-132(9)). For example, horizontal frame members
may be fixed between the vertical frame members via apertures
(e.g., apertures 224) formed in the vertical frame members.
[0062] Operation 506 may be followed by operation 508, which
represents displacing or sliding the permeable member into the
front of the data center rack door. For example, the permeable
member may be displaced or slid down substantially an entire length
(e.g., length 142) of the vertical frame members until a bottom
horizontal edge (i.e., portion 232) of the permeable member is
flush with a bottom edge of the bottom horizontal frame member
(e.g., horizontal frame member 132(1)), and a top horizontal edge
(e.g., portion 306) of the permeable member is flush with a top
edge of the top horizontal frame member (e.g., horizontal frame
member 132(N)).
[0063] Process 500 may be completed with operation 510, which
represents installing a bottom cap (e.g., bottom cap 228) and a top
cap (e.g., top cap 302) to the data center rack door. For example,
the bottom cap may be fixed to a bottom edge (e.g., bottom edge
230) of the data center rack door to cover the bottom horizontal
edge of the permeable member, and the top cap may be fixed to a top
edge (e.g., top edge 304) of the data center rack door to cover the
top horizontal edge of the permeable member.
CONCLUSION
[0064] Although the subject matter has been described in language
specific to structural features and/or methodological acts, it is
to be understood that the subject matter defined in the appended
claims is not necessarily limited to the specific features or acts
described. Rather, the specific features and acts are disclosed as
exemplary forms of implementing the claims.
* * * * *