Field of Invention

The present invention relates generally to couplings, and more particularly to blind mate couplings for use with electronic devices.

Background

Electronic devices, such as computer servers, generate heat during operation, and therefore a cooling system is used to cool the electronic devices. For example, air may be blown over the electronic devices or a water-based fluid may be circulated through a heat exchanger coupled to the electronic devices to cool the devices.

In a data center that houses racks of servers, the amount of air or water- based fluid required for heating may vary from rack to rack. The varied heat may arise from some racks having a greater density of electronic equipment or electric equipment operating at higher levels.

Summary of Invention

The present invention provides a coupling assembly including a first coupler having a first flow passage extending therethrough and a second coupler having a second flow passage extending therethrough. The second flow passage has a cross-sectional flow area that is greater than a cross-sectional flow area of the first flow passage. In this way, the coupling assembly can accommodate volumetric expansion of two-phase fluid that enters a heat- generating component via the first coupler and exits via the second coupler.

The foregoing and other features of the invention are hereinafter described in greater detail with reference to the accompanying drawings.

Brief Description of the Drawings

Fig. 1 is a perspective cross-sectional view of an exemplary coupling assembly according to the invention.

Fig. 2 is a side cross-sectional view of the exemplary coupling assembly according to the invention. Fig. 3 is another side cross-sectional view of the exemplary coupling assembly according to the invention.

Fig. 4 is still another side cross-sectional view of the exemplary coupling assembly according to the invention.

Detailed Description

The principles of the present application have particular application to blind mate quick connect/disconnect couplings for connecting a source of fluid, such as a two-phase refrigerant, to a heat-generating component, such as a rack of servers in a data center to cool the rack of serves, and thus will be described below chiefly in this context. It will of course be appreciated, and also

understood, that the principles of the invention may be useful in other fluid coupling applications where it is desirable to make a connection without the use of tools.

Turning now to Fig. 1 , an exemplary quick connect/disconnect coupling assembly is illustrated generally at reference numeral 10. The coupling system 10 includes first and second couplers 12 and 14, herein referred to as first and second female couplers, and third and fourth couplers 16 and 18, herein referred to as first and second male couplers. The first female and male couplers 12 and 16 and the second female and male couplers 14 and 18 may be connected to provide a fluid, such as a two-phase dielectric fluid, such as a two-phase refrigerant, to cool components in a data center. When connected, the second male and female couplers 14 and 18 serve as inlet couplers to deliver two-phase refrigerant to a heat-generating component, where the fluid absorbs heat, and then exits the heat-generating component through the first female and male couplers 12 and 16 that serve as outlet couplers. For example, the female couplers 12 and 14 may be coupled to a server blade and the male couplers 16 and 18 coupled to a server rack such that when the server blade is positioned in the rack, two-phase refrigerant flows through the couplers.

Referring now to Fig. 2 and the female couplers in detail, the first female coupler 12 includes a body 22, a valve assembly 24, and an adapter 26. The body 22 has axially inner and axially outer ends 28 and 30 and an axially extending cavity 32 defining with the valve assembly 24 a first flow passage 33. The axially extending cavity 32 defines a first cavity portion 38 for receiving the male coupler 16 at the axially inner end 28 and a second cavity portion 40 for receiving the adapter 26 at the axially outer end 30. The adapter 26, which may be coupled to a suitable tube 27 in any suitable manner, is coupled to the body 22 in any suitable manner, such as by threads 42 on an outer surface of the adapter 26 that mate with threads 44 on an inner circumferential surface 46 of the body 22 at the outer end 30. The adapter 26 includes a groove 48 for a suitable seal, such as an o-ring, to seal the adapter 26 to the body 22.

Similarly, the second female coupler includes a body 52, a valve assembly 54, and an adapter 56. The body 52 has axially inner and axially outer ends 58 and 60 and an axially extending cavity 62 defining with the valve assembly 54 a second flow passage 63. The axially extending cavity 62 defines a first cavity portion 68 for receiving the male coupler 18 at the axially inner end 58 and a second cavity portion 70 for receiving the adapter 56 at the axially outer end 60. The adapter 56, which may be coupled to a suitable tube 57 in any suitable manner, is coupled to the body 52 in any suitable manner, such as by threads 72 on an outer surface of the adapter 56 that mate with threads 74 on an inner circumferential surface 76 of the body 52 at the outer end 60. The adapter 56 includes a groove 78 for a suitable seal, such as an o-ring, to seal the adapter 56 to the body 52.

To accommodate volumetric expansion of the two-phase fluid after it has absorbed heat, such as when the two-phase refrigerant at least partially boils, the first flow passage 33 has a cross-sectional flow area that is greater than a cross-sectional flow area of the second flow passage 63. In an embodiment, the cross-sectional flow area of the first flow passage 33 is at least 25% greater than the cross-sectional flow area of the second flow passage 63. In a further embodiment, the cross-sectional flow area of the first flow passage 33 is at least 50% greater than the cross-sectional flow area of the second flow passage 63. In another embodiment, the cross-sectional flow area of the first flow passage 33 is at least 100% greater than the cross-sectional flow area of the second flow passage 63.

Referring now to the male couplers in detail, the first male coupler 16 includes a body 90, a valve assembly 92, and an adapter 94. The body 90 has an axially inner end 96 configured to be received in the cavity portion 38 of the female coupler 12, an axially outer end 98, and an axially extending cavity 100 extending therethrough and defining with the valve assembly 92 a first flow passage 101 . The valve assembly 92 and the adapter 94 are configured to be received in the cavity 100. The adapter 94, which may be coupled to a suitable tube 95 in any suitable manner, is coupled to the body 90 in any suitable manner, such as by threads 102 on an outer surface of the adapter 94 that mate with threads 104 on an inner circumferential surface 106 of the body 90 at the outer end 98.

Similarly, the second male coupler 18 includes a body 1 10, a valve assembly 1 12, and an adapter 1 14. The body 1 10 has an axially inner end 1 16 configured to be received in the cavity portion 68 of the female coupler 14, an axially outer end 1 18, and an axially extending cavity 120 extending

therethrough and defining with the valve assembly 1 12 a first flow passage 121 . The valve assembly 1 12 and the adapter 1 14 are configured to be received in the cavity 120. The adapter 1 14, which may be coupled to a suitable tube 1 15 in any suitable manner, is coupled to the body 1 10 in any suitable manner, such as by threads 122 on an outer surface of the adapter 1 14 that mate with threads 124 on an inner circumferential surface 126 of the body 1 10 at the outer end 1 18.

To accommodate volumetric expansion of the two-phase fluid after it has absorbed heat, the first flow passage 101 has a cross-sectional flow area that is greater than a cross-sectional flow area of the second flow passage 121 . In an embodiment, the cross-sectional flow area of the first flow passage 101 is at least 25% greater than the cross-sectional flow area of the second flow passage 121 . In a further embodiment, the cross-sectional flow area of the first flow passage 101 is at least 50% greater than the cross-sectional flow area of the second flow passage 121 . In another embodiment, the cross-sectional flow area of the first flow passage 101 is at least 100% greater than the cross-sectional flow area of the second flow passage 121 .

To allow the first and second female couplers 12 and 14 to couple respectively to the first and second male couplers 16 and 18 at the same time and act in conjunction with one another, thereby moving the valve assemblies 24, 54, 92, and 1 12 to the fully open positions, the coupling pairs engage one another in the same travel distance in a longitudinal direction. The first and second female couplers 12 and 14 are disposed in a housing 150 and laterally spaced from one another. When disposed in the housing 150, a longitudinal axis of the first female coupler 12 is parallel to a longitudinal axis of the second female coupler 14, and the first and second female couplers 12 and 14 are laterally aligned in a direction transverse the longitudinal axes.

The housing 150 may include, for example, first and second openings 152 and 154 through which the first and second female couplers 12 and 14 extend respectively. The first and second openings 152 and 154 have shoulders 156 and 158, respectively, which are abutted by flanges 160 and 162 on the bodies 22 and 52 when the first and second female couplers 12 and 14 are disposed in the housing 150. The shoulders 156 and 158 prevent the first and second female couplers 12 and 14 from moving longitudinally in a direction away from the first and second male couplers 16 and 18.

The first and second openings 152 and 154 also have diameters that are greater than diameters of the first and second female couplers 12 and 14, respectively, to allow the first and second female couplers 12 and 14 to float in a lateral direction. For example, the first and second openings 152 and 154 may each have a first diameter greater than a diameter of the respective flanges 160 and 162, and a second diameter, which is less than the first diameter, greater than the respective body 22 and 52. If, for example, the second female coupler 14 is not aligned with the second male coupler 18, the second female coupler 14 may float within the opening 154 in the lateral direction to align the couplers to allow the second male coupler 18 to be received in the second female coupler 14.

Similar to the first and second female couplers 12 and 14, the first and second male couplers 16 and 18 are disposed in a housing 170 and laterally spaced from one another. When disposed in the housing 170, a longitudinal axis of the first male coupler 16 is parallel to a longitudinal axis of the second male coupler 18, and the first and second male couplers 16 and 18 are laterally aligned in a direction transverse the longitudinal axes. The housing 170 may include, for example, first and second openings 172 and 174 through which the first and second male couplers 16 and 18 extend respectively. The first and second openings 172 and 174 have shoulders 176 and 178, respectively, which are abutted by flanges 180 and 182 on the bodies 90 and 1 10 when the first and second male couplers 16 and 18 are disposed in the housing 170. The shoulders 176 and 178 prevent the first and second male couplers 16 and 18 from moving longitudinally in a direction away from the first and second female couplers 12 and 14.

The housings 150 and 170 may be coupled in any suitable manner to engage the female couplers 12 and 14 with the male couplers 16 and 18. For example, a bolt 190 may be provided that extends through an opening 192 in the housing 50 and through an opening 194 in the housing 170. The bolt has threads that mate with threads in the opening 194. Alternatively, a protrusion integrally formed with or coupled to one of the housings 150 and 170 may be provided that is received in an opening in the other of the housings 150 and 170. The protrusion may include one or more detents that may be urged into one or more corresponding detent recesses in the opening in the other of the housings 150 and 170. Additionally or alternatively, threads may be provided on an inner surface of the body 22, 52 of one or both of the female couplers 12 and 14 to mate with threads on an outer surface of the body 90, 1 10 of the respective male coupler 16 and 18, and/or a suitable locking device, such as detents, may be provided on the male and female couplers to lock the male and female couplers.

Referring now to the valve assembly 24 in detail, the valve assembly 24 is disposed in the axially extending cavity 32 and includes a poppet stem 200, a sleeve 202 surrounding the poppet stem 200, and a resilient member 204, such as a spring, biasing the sleeve 202 in a first position as shown in Fig. 2.

Disposed in a seal groove 206 in the sleeve 202 is a suitable seal, such as o- ring 208, that seals the sleeve 202 to the inner circumferential surface 46 of the body 22.

When the sleeve 202 is in the first position, a radially outwardly projecting portion 210 of the poppet stem, herein referred to as a poppet head, is seated against an end face of the sleeve 202 and sealed to the sleeve 202 by a suitable seal 212, such as a bonded elastomeric material or o-ring, such as neoprene. The poppet head 210 may have a crown having a suitable material, such as rubber. The poppet head 210 is seated against the seal 212 to prevent fluid flow through the cavity 32 when the sleeve 202 is in the first position. When the sleeve 202 is moved to a second position shown in Fig. 4 away from the poppet head 210, fluid flows through the cavity 32 around the poppet stem 200 and in- between the poppet stem 200 and the sleeve 202. The sleeve 202 is in the first position when the female and male couplers 12 and 16 are disconnected and in the second position when the couplers are connected.

The valve assembly 24 also includes a spider 214 surrounding the poppet stem 200 opposite the poppet head 210. The spider 214 is coupled to the poppet stem 200 in any suitable manner and includes a hub 216 and a plurality of circumferentially spaced legs 218 extending radially outwardly from the hub 216. As fluid flows through the cavity 32 (when the sleeve 202 is in the second position), the fluid flows between the plurality of circumferentially spaced legs 218. A front side 220 of the plurality of circumferentially spaced legs 218 facing the poppet head 210 serves as a seat for an outer end of the resilient member 204, and a backside 222 of the sleeve 202 serves as a seat for an inner end of the resilient member 204. A backside 224 of the plurality of circumferentially spaced legs 218 facing the adapter 26 abut an end face of the adapter 26 when the adapter 24 is coupled to the body 22 to retain the valve assembly 24 within the body 22, and the legs 218 abut a reduced diameter portion 226 of the body 22 to prevent the legs 218 and stem 200 from moving towards the sleeve 202.

Referring now to the valve assembly 54 in detail, which is similar to the valve assembly 24, the valve assembly 54 is disposed in the axially extending cavity 62 and includes a poppet stem 230, a sleeve 232 surrounding the poppet stem 230, and a resilient member 234, such as a spring, biasing the sleeve 232 in a first position as shown in Fig. 2. Disposed in a seal groove 236 in the sleeve 232 is a suitable seal, such as o-ring 238, that seals the sleeve 232 to the inner circumferential surface 76 of the body 52.

When the sleeve 232 is in the first position, a radially outwardly projecting portion 240 of the poppet stem, herein referred to as a poppet head, is seated against an end face of the sleeve 232 and sealed to the sleeve 232 by a suitable seal 242, such as a bonded elastomeric material or o-ring, such as neoprene. The poppet head 240 may have a crown having a suitable material, such as rubber. The poppet head 240 is seated against the seal 242 to prevent fluid flow through the cavity 52 when the sleeve 232 is in the first position. When the sleeve 232 is moved to a second position shown in Fig. 4 away from the poppet head 240, fluid flows through the cavity 52 around the poppet stem 200 and in- between the poppet stem 230 and the sleeve 232. The sleeve 232 is in the first position when the female and male couplers 14 and 18 are disconnected and in the second position when the couplers are connected.

The valve assembly 54 also includes a spider 244 surrounding the poppet stem 230 opposite the poppet head 240. The spider 244 is coupled to the poppet stem 230 in any suitable manner and includes a hub 246 and a plurality of circumferentially spaced legs 248 extending radially outwardly from the hub 246. As fluid flows through the cavity 52 (when the sleeve 232 is in the second position), the fluid flows between the plurality of circumferentially spaced legs 248. A front side 250 of the plurality of circumferentially spaced legs 248 facing the poppet head 240 serves as a seat for an outer end of the resilient member 234, and a backside 252 of the sleeve 232 serves as a seat for an inner end of the resilient member 234. A backside 254 of the plurality of circumferentially spaced legs 248 facing the adapter 56 abut an end face of the adapter 56 when the adapter 56 is coupled to the body 52 to retain the valve assembly 54 within the body 52, and the legs 248 abut a reduced diameter portion 256 of the body 52 to prevent the legs 248 and stem 230 from moving towards the sleeve 232.

Referring now to the valve assembly 92 in detail, the valve assembly 92 is disposed in the axially extending cavity 100 and includes a poppet stem 270 and a resilient member 272, such as a spring, biasing the poppet stem 270 in a first position shown in Fig. 2. When the poppet stem 270 is in the first position, the spring 272 biases the poppet stem 270 against a valve seat 274 projecting radially inwardly from the body 90, thereby preventing fluid from flowing through the cavity 100. The valve seat 274 may be any suitable material, such as a bonded elastomeric material, such as neoprene. As shown, the poppet stem 270 includes a radially outwardly extending portion 276, herein referred to as a poppet head, which is seated against the valve seat 274, and which may have a crown having a suitable material, such as rubber. The poppet stem 270 is in the first position when the female and male couplers 12 and 16 are disconnected. When the poppet stem 270 is in a second position shown in Fig. 4, the poppet stem 270 is moved away from the valve seat 274 to allow fluid flow through the cavity 100.

The valve assembly 92 also includes a spider 280 surrounding the poppet stem 270, where the poppet stem 270 is movable relative to the spider 280. The spider includes a hub 282 and a plurality of circumferentially spaced legs 284 extending radially outwardly from the hub 282. As fluid flows through the cavity 100 (when the poppet stem 270 is in the second position), the fluid flows between the plurality of circumferentially spaced legs 284. A front side 286 of the plurality of circumferentially spaced legs 284 facing the poppet head 276 serves as a seat for an outer end of the resilient member 272, and a backside 288 of the poppet head 276 serves as a seat for an inner end of the resilient member 272. A backside 290 of the plurality of circumferentially spaced legs 284 facing the adapter 94 abuts an end face 292 of the adapter 94 when the adapter 94 is coupled to the body 90 to retain the valve assembly 92 within the body 90.

Referring now to the valve assembly 1 12 in detail, which is similar to the valve assembly 92, the valve assembly 1 12 is disposed in the axially extending cavity 120 and includes a poppet stem 300 and a resilient member 302, such as a spring, biasing the poppet stem 300 in a first position shown in Fig. 2. When the poppet stem 300 is in the first position, the spring 302 biases the poppet stem 300 against a valve seat 304 projecting radially inwardly from the body 1 10, thereby preventing fluid from flowing through the cavity 120. The valve seat 304 may be any suitable material, such as a bonded elastomeric material, such as neoprene. As shown, the poppet stem 300 includes a radially outwardly extending portion 306, herein referred to as a poppet head, which is seated against the valve seat 304, and which may have a crown having a suitable material, such as rubber. The poppet stem 300 is in the first position when the female and male couplers 14 and 18 are disconnected. When the poppet stem 300 is in a second position shown in Fig. 4, the poppet stem 300 is moved away from the valve seat 304 to allow fluid flow through the cavity 120. The valve assembly 1 12 also includes a spider 310 surrounding the poppet stem 300, where the poppet stem 300 is movable relative to the spider 310. The spider includes a hub 312 and a plurality of circumferentially spaced legs 314 extending radially outwardly from the hub 312. As fluid flows through the cavity 120 (when the poppet stem 300 is in the second position), the fluid flows between the plurality of circumferentially spaced legs 314. A front side 316 of the plurality of circumferentially spaced legs 314 facing the poppet head 306 serves as a seat for an outer end of the resilient member 302, and a backside 318 of the poppet head 306 serves as a seat for an inner end of the resilient member 302. A backside 320 of the plurality of circumferentially spaced legs 314 facing the adapter 1 14 abuts an end face 322 of the adapter 1 14 when the adapterl 14 is coupled to the body 1 10 to retain the valve assembly 1 12 within the body 1 10.

Referring now to Figs. 2 and 3, the connection of the female and male couplers will be discussed in detail. Referring initially to Fig. 3, as the female and male couplers are advanced towards one another, for example by tightening the bolt 190, the axially inner ends 96 and 1 16 of the male couplers 16 and 18 are received in the respective cavity portions 38 and 68 of the female couplers 12 and 14. During the coupling, shoulders 330 and 332 at the axially inner ends 96 and 1 16 of the male couplers 16 and 18 come into contact with the respective poppet sleeves 202 and 232, and end faces of the poppet heads 276 and 306 come into contact with the respective poppet heads 210 and 240. If the axes of the male and female couplers are not aligned, the axially inner ends 28 and 58 of the female couplers 12 and 14 may be tapered to guide corresponding angled portions at the axially inner ends 96 and 1 16 into the cavity portions 38 and 68 to align the axes.

As the couplers are advanced from the position shown in Fig. 3 to the fully opened position in Fig. 4, the shoulders 330 and 332 at the axially inner ends 96 and 1 16 simultaneously move the poppet sleeves 202 and 232 away from the poppet heads 210 and 240 to open the valve assemblies 24 and 54. The shoulders 330 and 332 move the sleeves 202 and 232 until the axially inner ends 96 and 1 16 simultaneously contact and compress respective suitable seals, such as o-rings 334 and 336 at inner walls 338 and 340 in the cavity portions 38 and 68, respectively.

As the shoulders 330 and 332 move the sleeves 202 and 232, the poppet heads 210 and 240 move the poppet stems 270 and 300 off of their respective valve seats 274 and 304 against the force of the resilient members 272 and 302 to open the valve assemblies 92 and 1 12. As this occurs, the poppet heads 210 and 240 move into the cavities 100 and 120 and the poppet stems 270 and 300 move relative to the spiders 290 and 310.

A distance the poppet stem 200 travels in the longitudinal direction from the closed position to the fully open position is the same as a distance the poppet 230 travels in the longitudinal direction from the closed position to the fully open position. Similarly, a distance the poppet stem 270 travels in the longitudinal direction from the closed position to the fully open position is the same as a distance the poppet 300 travels in the longitudinal direction from the closed position to the fully open position.

Once the female couplers 12 and 14 are coupled to the male couplers 16 and 18, fluid can flow from the tube 57 through the adapter 56, between the legs 248 and then through the second flow passage 33 between the sleeve 232 and the poppet stem 230 into the male coupler 18. The fluid then flows through the second flow passage 121 , between the legs 314 into the adapter 1 14 and then through the tube 1 15 to a heat-absorbing component. The fluid absorbs heat in and/or around the heat-generating component and then exits the heat- generating component through the tube 95. The fluid flows from the tube 95 through the adapter 94, between the legs 284 and then through the first flow passage 101 into the female coupler 12. The fluid then flows through the first flow passage 33 between the sleeve 202 and the poppet stem 200, between the legs 218, through the adapter 26 and into the tube 27. The fluid then may be delivered from the tube 27 to a suitable heat exchanger to condense the fluid and reject the heat absorbed by the fluid.

Although the invention has been shown and described with respect to a certain embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a "means") used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application.