Packaging system for modular power cells

• US 20070048574A1
• Filed: 08/29/2006
• 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 7,892,670 B2
• Time in Patent Office: Days
• US Class Current: 429/435
• 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 power delivery system includes a group of removable power cells. Each power cell includes a water cooled heat sink, an air intake, and an air output. The system also includes a heat exchanger. The heat exchanger draws air from the cells, cools it, and recirculates the cooled air to the cells via each cell'"'"'s air intake. The cell may be designed so that components that are not near the heat sink are cooled by air from the intake before that air reaches the heat sink.

Claims

1. A power delivery system, comprising:

a plurality of removable power cells positioned within a housing structure, each power cell comprising a water cooled heat sink, an air intake, and an air output; and

a heat exchanger;

wherein each cell is positioned to receive air into the air intake and expel the air into an air plenum; and

wherein the heat exchanger is positioned to receive the air from the air plenum, cool the air, and recirculate the cooled air to the cells via each cell'"'"'s air intake.

2. The system of claim 1 wherein, during operation, the air that is expelled into the air plenum by a cell is warmer than the air that is received into the air intake of the cell.

3. The system of claim 2 wherein:

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

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

4. The system of claim 1 wherein each power cell comprises a plurality of capacitor connectors and a plurality of transistors.

5. The system of claim 4, wherein the capacitor connectors are positioned closer to the air intake when compared to the position of the heat sink, and the heat sink is positioned closer to the air outlet when compared to the position of the capacitor connectors.

6. The system of claim 5, wherein during operation, most air circulating through the cell contacts the capacitor connectors before contacting the heat sink.

7. The system of claim 5, wherein each power cell further comprises a circuit board that is positioned closer to the air intake when compared to the position of the heat sink.

8. The system of claim 1 further comprising:

a back plane positioned between the cells and the air plenum;

a plurality of power delivery busses positioned within the air plenum to deliver power to the cells; and

a plurality of power return busses positioned within the air plenum to receive power from the cells and deliver the power to a load.

9. The system of claim 1, further comprising a water delivery manifold and a water return manifold, wherein each manifold comprises a plurality of self-sealing connections, wherein each connection opens when a cell is connected to the connection and closes when a cell is removed from the connection.

10. A power delivery system, comprising:

a plurality of removable power cells positioned within a housing structure, each power cell comprising an input bus, an output bus, an air intake, and an air output, and a water cooled sink that is connected to a water intake and a water output;

a water delivery manifold and a water return manifold, wherein each manifold comprises a plurality of self-sealing connections, wherein each connection opens when a cell is connected to the connection and closes when a cell is removed from the connection;

an air plenum; and

a heat exchanger that receives the air from the air plenum, cools the air, and recirculates the cooled air to the cells via each cell'"'"'s air intake;

wherein each cell is positioned to receive air and expel the air into the air plenum, and wherein each cell is further positioned to receive water through its water intake and expel the water from its water output.

11. The system of claim 10 wherein, during operation:

the air that is expelled into the air plenum by a cell is warmer than the air that is received into the air intake of the cell; and

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

12. The system of claim 10 wherein each power cell comprises a plurality of capacitor connectors and a plurality of transistors.

13. The system of claim 12, wherein the capacitor connectors are positioned closer to the air intake when compared to the position of the heat sink, and the heat sink is positioned closer to the air outlet when compared to the position of the capacitor connectors.

14. The system of claim 12, wherein during operation, most air circulating through the cell contacts the capacitor connectors before contacting the hear sink.

15. The system of claim 12, wherein each power cell further comprises a circuit board that is positioned closer to the air intake when compared to the position of the heat sink.

16. The system of claim 10 further comprising:

a back plane positioned between the cells and the air plenum;

a plurality of power delivery busses positioned within the air plenum to deliver power to the cells; and

a plurality of power return busses positioned within the air plenum to receive power from the cells and deliver the power to a load.

17. A power delivery system, comprising:

a plurality of removable power cells positioned within a housing structure, each power cell comprising an air intake, an air output, and a water cooled sink;

a water delivery manifold and a water return manifold connected to the water cooled sink, wherein each manifold comprises a plurality of self-sealing connections, wherein each connection opens when a cell is connected to the connection and closes when a cell is removed from the connection;

an air plenum; and

a heat exchanger that receives the air from the air plenum, cools the air, and recirculates the cooled air to the cells via each cell'"'"'s air intake;

wherein each cell is positioned to receive air and expel the air into the air plenum, and during operation, the air that is expelled into the air plenum by a cell is warmer than the air that is received into the air intake of the-cell;

wherein each power cell comprises a plurality of capacitor connectors, the capacitor connectors are positioned closer to the air intake when compared to the position of the heat sink, and the heat sink is positioned closer to the air outlet when compared to the position of the capacitor connectors.

18. The system of claim 17, wherein during operation, most air circulating through the cell contacts the capacitor connectors before contacting the heat sink.

19. The system of claim 17, wherein each power cell further comprises a circuit board that is positioned closer to the air intake when compared to the position of the heat sink.

20. The system of claim 17 further comprising:

a back plane positioned between the cells and the air plenum;

a plurality of power delivery busses positioned within the air plenum to deliver power to the cells; and

a plurality of power return busses positioned within the air plenum to receive power from the cells and deliver the power to a load.