Packaging method for modular power cells

• US 20070048561A1
• Filed: 08/31/2006
• Published: 03/01/2007
• Est. Priority Date: 08/31/2005
• Status: Active Grant

• Current Assignee: Innomotics GmbH
• Original Assignee: Continental Automotive GmbH (Continental AG)
• Inventors: Aiello, Marc, Cheesman, Edward, Jordan, Wayne
• Granted Patent: US 7,798,892 B2
• Time in Patent Office: Days
• US Class Current: 454/184
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change

Abstract

A method of operating a power delivery system that has at least one power cell includes directing air into the power cells to cool them, receiving the air from the cells, directing the air to a cooling system, and recirculating the cooled air to the power cells. Each cell may include an air intake, an air output, a water-cooled heat sink, and optionally a plurality of capacitor connectors and/or a circuit board. The air may be directed through the air intake to the air output so that air passes over the capacitor connectors and/or the circuit board before passing over the heat sink.

Claims

1. A method of operating a power delivery system having at least one power cell comprising:

directing air into a power cell to cool the cell;

receiving the air from the power cell, wherein the air received from the cell is warmer than the air directed into the cell; and

cooling the received air and recirculating it to the power cell.

2. The method of claim 1, wherein the cell is contained within a support structure having an air plenum, the cooling is provided by a heat exchanger, and the receiving comprises directing air through the air plenum from the cell to the heat exchanger.

3. The method of claim 1, wherein:

the cell comprises an air intake, an air output, a water-cooled heat sink, and a plurality of capacitor connectors;

the directing comprises directing the air through the air intake;

the receiving comprises receiving the air from the air output; and

the method further comprises passing the air over the water-cooled heat sink and the capacitor connectors so that the air passes over the capacitor connectors before passing over the heat sink.

4. The method of claim 3 wherein:

the cell'"'"'s heat sink is connected to a water intake and a water output; and

during operation, water that is expelled through the water output by the cell is warmer than water that is received into the water intake of the cell.

5. The method of claim 1, wherein:

the cell comprises an air intake, an air output, a water-cooled heat sink, and a circuit board;

the directing comprises directing the air through the air intake;

the receiving comprises receiving the air from the air output; and

the method further comprises passing the air over the water-cooled heat sink and the circuit board so that the air passes over the circuit board before passing over the heat sink.

6. The method of claim 1, wherein the cooling comprises cooling the air to approximately 55°

C.

7. The method of claim 1, wherein the recirculating reduces air ionization.

8. A method of operating a power delivery system having a plurality of power cells comprising:

directing air into a plurality of power cells, wherein each cell comprises an air intake, an air output, a water-cooled heat sink, and a plurality of capacitor connectors, wherein the directing comprises directing the air through the air intake of each cell;

passing the air over the water-cooled heat sink of and the capacitor connectors of each cell so that the air passes over the capacitor connectors before passing over the heat sink;

receiving the air from the power cells; and

cooling the received air and recirculating it to the power cells.

9. The method of claim 8, wherein the cells are contained within a support structure having an air plenum, the cooling is provided by a heat exchanger, and the receiving comprises directing air through the air plenum from the cells to the heat exchanger.

10. The method of claim 8 wherein:

each cell'"'"'s heat sink is connected to a water intake and a water output; and

during operation, water that is expelled through the water output by a cell is warmer than water that is received into the water intake of the same cell.

11. The method of claim 8, wherein:

each cell further comprises a circuit board;

the passing further comprises passing the air over the circuit board before the air passes over the heat sink of a cell.

12. The method of claim 8, wherein the recirculating reduces air ionization.