The proliferation of data centers to meet growing AI adoption and other digital services is also increasing the demands placed on the equipment inside and outside these structures. Higher equipment densities and energy consumption can introduce challenges that are felt and heard.
More computing power is packed into racks and enclosures, generating heat that needs to be removed. And the fans, cooling systems, generators, and other equipment supporting those workloads create a much noisier environment.
Noise often makes the impact especially noticeable. Employees and technicians work around these systems, and sound from exterior equipment can reach nearby communities. But data center operators can’t simply scale back the cooling and supporting systems when they become noisy without potentially affecting equipment performance or reliability.
Addressing these challenges is a collaborative process that often requires bold thinking. At Polymer Technologies, we work with OEMs and engineering teams to identify materials that help manage thermal and acoustic energy while supporting the equipment’s performance requirements.
In this article, we’ll cover:
- Why increasing computing density is making temperature control more challenging in data centers.
- How airflow, hot spots, and evolving cooling strategies affect equipment performance.
- Where equipment noise originates and how it can travel through enclosures, openings, and surrounding spaces.
- How engineers can balance thermal and acoustic requirements when selecting insulation for different data center systems
Thermal challenges in data center cooling
Air cooling has traditionally been used to manage heat generated in data centers. Conditioned air is moved toward the computing equipment and heated exhaust is carried away. However, higher-density computing environments powering AI may require liquid-cooling technologies, including direct-to-chip systems and cooling distribution units (CDUs), to transfer heat more directly from high-powered components.
Regardless of the cooling method, heat still has to be transferred away from the equipment.
In air-cooled environments, cooled air may not reach the components that need it, while hot exhaust can recirculate toward server inlets. This can create localized hot spots even when the overall room temperature seems normal.
As equipment temperatures rise, server and equipment fans may increase speed, adding both energy use and noise. If heat continues to build, equipment performance and reliability can eventually be affected. But solving the problem with insulation materials is not always straightforward.
Engineers need to consider where heat originates, how it moves through the equipment, and what may interrupt that path. Environmental factors such as airflow, temperature exposure, moisture, available space, and applicable flammability requirements can also influence which material is selected and incorporated into the design.
Managing noise from data center equipment
How far equipment noise travels depends partly on how the equipment is housed and ventilated. Enclosure panels can transmit sound, while doors, service hatches, plenums, louvers, and other necessary openings often create paths for noise to escape.
Finding the right acoustic insulation is an important part of equipment design. Materials should help control sound while still allowing air to reach critical components and meeting the system’s thermal requirements.
Where the sound travels will determine its impact
Inside the facility
Technicians and other data center staff may spend extended periods around operating equipment. OSHA workplace noise requirements could apply depending on sound levels and exposure duration. OSHA requires hearing conservation measures when employee exposure reaches an eight-hour time-weighted average of 85 dBA and establishes an eight-hour permissible exposure level of 90 dBA.
Outside the facility
Sound from exterior generators and other mechanical equipment can reach nearby properties and communities. As more data centers are developed near populated areas, controlling noise from exterior equipment helps reduce persistent sound reaching the neighbors.
Solving thermal and acoustic problems across data center systems
Server and rack equipment
Server and rack equipment bring several challenges in a compact space. Heat is concentrated around high-powered components, cooling air needs a controlled path through the equipment, and high-speed fans are noisy.
POLYDAMP® Melamine Foam (PMF) and POLYDAMP® Hydrophobic Melamine Foam (PHM) work well for traditional acoustical and thermal insulation. These materials offer higher temperature resistance and flammability ratings for UL94 V-0 or ASTM E84/UL 723 requirements. PHM also has excellent moisture-resistant properties. POLYFORM® molded foams provide a more tailored approach. Airpaths can be designed directly into the molded part to control airflow to where it is needed most.
Cooling and mechanical equipment
As noted above, cooling systems can introduce acoustic and thermal challenges of their own. Air-cooled systems need effective airflow, and liquid-cooled equipment can create concerns around heat transfer and condensation. Fans, motors, and pumps can also contribute to the overall noise level.
PMF and PHM are suitable options depending on the equipment design and operating environment. Custom molded foam offers more flexibility around complex equipment layouts, helping engineers manage airflow and add acoustic absorption in critical areas.
Equipment enclosures, doors, and access points
Sound can transmit through enclosure surfaces or escape through access points. Doors, service hatches, plenums, and other openings may also need insulation without interfering with cooling or maintenance.
For these applications, POLYDAMP® Acoustical Foam (PAF) should be considered. PAF is an open-cell urethane foam that provides strong sound absorption for a given thickness. It can be a good fit for enclosure panels, doors, hatches, and other areas. PMF or PHM may be better suited when the application calls for higher temperature resistance or different flammability requirements.
Power and generator equipment
Backup generators and other power infrastructure can generate significant mechanical noise. Enclosures play an important role in limiting how much of that sound reaches the surrounding environment. Noise needs to be managed without limiting ventilation, service access, or the thermal conditions around the equipment.
Depending on the equipment and enclosure, PAF, PMF, or PHM may be the best material for the application.
Bring your acoustic and thermal challenges to Polymer
Every data center application comes with its own acoustic and thermal requirements, and those requirements have become more complex with more compute. We work with OEMs and engineering teams to understand how the equipment operates and identify materials that support the design.
From standard insulation products to custom molded foam, our team can help you find the right approach for your application.
Have a data center noise or temperature challenge? Talk to the experts at Polymer.