ENERGY STORAGE DEVICE

• US 20080265586A1
• Filed: 03/18/2008
• Published: 10/30/2008
• Est. Priority Date: 04/27/2007
• Status: Active Grant

• Current Assignee: Flextronics International Limited
• Original Assignee: Flextronics International Limited
• Inventors: Like, Nathan, Gutman, Robert F., York, Michael T., Coulter, Christopher
• Granted Patent: US 8,134,343 B2
• Time in Patent Office: Days
• US Class Current: 290/38R
• CPC Class Codes: B60R 16/04 Arrangement of batteries
• CPC Class Codes: F02N 11/0866 comprising several power sources, e.g. battery and capacitor or two batteries
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• CPC Class Codes: H01G 2/04 specially adapted for mounting on a chassis
• CPC Class Codes: H05K 7/20518 Unevenly distributed heat load, e.g. different sectors at different temperatures, localised cooling, hot spots
• CPC Class Codes: H05K 7/20854 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20863 takes precedence
• CPC Class Codes: H05K 7/209 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20909 takes precedence

Abstract

An energy storage device for storing energy for starting an internal combustion engine of a motor vehicle includes a DC-DC converter, a plurality of capacitors connected electrically to the DC-DC converter, and a housing for containing the DC-DC converter and the capacitors. The DC-DC converter converts a voltage provided by the motor vehicle'"'"'s battery to a second voltage stored by the capacitors. During an engine start cycle, energy discharges from the capacitors to the starter motor of the engine, wherein the stored voltage of the capacitors provides energy to start the engine. The capacitors are recharged by the vehicle'"'"'s battery. A thermally insulated barrier separates the DC-DC converter and the capacitors. The housing may be sized and shaped substantially as that of a standard motor vehicle battery, enabling the energy storage device to be installed within the motor vehicle as a substitute for one or more of the vehicle'"'"'s batteries.

Claims

1. An energy storage device for starting an engine of a motor vehicle, comprising:

voltage conversion means for converting a first voltage provided from an electrical system of the motor vehicle to a second voltage;

storage means, electrically connected to said voltage conversion means, for storing the second voltage, the second voltage providing energy for starting the engine of the motor vehicle; and

housing means for housing said voltage conversion means and said storage means, said voltage conversion means and said storage means are substantially contained within said housing means.

2. The energy storage device of claim 1, wherein said storage means includes at least one capacitor.

3. The energy storage device of claim 2, wherein said at least one capacitor includes a plurality of capacitors.

4. The energy storage device of claim 3, further comprising a retention structure for providing structural support for said plurality of capacitors.

5. The energy storage device of claim 4, wherein said plurality of capacitors is arranged in a first column and a second column by said retention structure.

6. The energy storage device of claim 5, wherein said retention structure includes a first structural member positioned intermediate said first and second columns, a second structural member and a third structural member, said first column being positioned intermediate said first structural member and said second structural member, and said second column being positioned intermediate said first structural member and said third structural member.

7. The energy storage device of claim 6, wherein said first structural member includes a first surface and a second surface opposite thereof, said first surface having a first plurality of recesses and said second surface having a second plurality of recesses, each of said first plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said first column, and each of said second plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said second column.

8. The energy storage device of claim 7, wherein said second structural member includes a first surface having a third plurality of recesses and said third structural member includes a first surface having a fourth plurality of recesses, each of said third plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said first column, and each of said fourth plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said second column.

9. The energy storage device of claim 8, wherein said storage means includes a second plurality of capacitors.

10. The energy storage device of claim 9, further comprising a second retention structure for providing structural support for said second plurality of capacitors.

11. The energy storage device of claim 10, wherein said second plurality of capacitors is arranged in a first column and a second column by said second retention structure.

12. The energy storage device of claim 11, wherein said second retention structure includes a first structural member positioned intermediate said first and second columns of said second plurality of capacitors, a second structural member and a third structural member, said first column of said second plurality of capacitors being positioned intermediate said first structural member of said second retention structure and said second structural member of said second retention structure, and said second column of said second plurality of capacitors being positioned intermediate said first structural member of said second retention structure and said third structural member of said second retention structure.

13. The energy storage device of claim 12, wherein said first structural member of said second retention structure includes a first surface and a second surface opposite thereof, said first surface of said first structural member of said second retention structure having a first plurality of recesses, and said second surface of said first structural member of said second retention structure having a second plurality of recesses, each of said first plurality of recesses of said first structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said first column thereof, and each of said second plurality of recesses of said first structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said second column thereof.

14. The energy storage device of claim 13, wherein said second structural member of said second retention structure includes a first surface having a third plurality of recesses, and said third structural member of said second retention structure includes a first surface having a fourth plurality of recesses, each of said third plurality of recesses of said second structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said first column thereof, and each of said fourth plurality of recesses of said third structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said second column thereof.

15. The energy storage device of claim 1, wherein said voltage conversion means includes a DC-DC converter.

16. The energy storage device of claim 15, wherein the electrical system of the motor vehicle includes a battery, the first voltage being provided from the battery.

17. The energy storage device of claim 16, wherein said DC-DC converter includes controlling means for controlling the conversion of the first voltage to the second voltage.

18. The energy storage device of claim 17, wherein said controlling means includes a microprocessor.

19. The energy storage device of claim 18, wherein the second voltage is greater than the first voltage.

20. The energy storage device of claim 17, wherein said DC-DC converter includes monitoring means for monitoring at least one condition of said storage means.

21. The energy storage device of claim 20, wherein said at least one condition of said storage means includes a temperature.

22. The energy storage device of claim 20, wherein said at least one condition of said storage means includes the second voltage.

23. The energy storage device of claim 22, wherein said controlling means maintains the second voltage stored by said storage means within a predetermined range.

24. The energy storage device of claim 10, wherein said housing means includes a first area for housing said voltage conversion means and a second area for housing said first and second retention structures.

25. The energy storage device of claim 24, wherein said second area of said housing means includes a first chamber and a second chamber, said first retention structure being installed removably within said first chamber, and said second retention structure being installed removably within said second chamber.

26. The energy storage device of claim 25, further comprising barrier means, positioned within said housing means, for substantially separating said first and second areas of said housing means from one another.

27. The energy storage device of claim 26, wherein said barrier means includes a plate having a first surface and a second surface opposite thereof, said first surface of said plate is positioned within said first area of said housing means, and said second surface of said plate is positioned within said second area of said housing means.

28. The energy storage device of claim 27, wherein said plate is thermally insulated.

29. The energy storage device of claim 28, wherein said voltage conversion means is mounted to said first surface of said plate.

30. The energy storage device of claim 29, wherein said housing means includes a housing having a first end and a cover mounted removably to said first end.

31. The energy storage device of claim 30, wherein said housing is sized and shaped substantially to that of a motor vehicle battery housing.

32. The energy storage device of claim 30, wherein said first and second plurality of capacitors includes a net positive terminal and a net negative terminal.

33. The energy storage device of claim 32, further comprising a first electrical terminal connected electrically to said net negative terminal of said first and second plurality of capacitors, a positive terminal of a motor vehicle battery, and to a starter of the motor vehicle, and a second electrical terminal connected electrically to ground.

34. The energy storage device of claim 33, wherein said first and second electrical terminals are mounted to said first surface of said plate and extend outwardly from said cover of said housing.

35. The energy storage device of claim 32, further comprising a first electrical terminal connected electrically to said net negative terminal of said first and second plurality of capacitors and a positive terminal of a motor vehicle battery, a second electrical terminal connected electrically to ground, and a third electrical terminal electrically connected to said net positive terminal of said first and second plurality of capacitors and to a starter of the motor vehicle.

36. The energy storage device of claim 35, wherein said first, second and third electrical terminals are mounted to said first surface of said plate and extend outwardly from said cover of said housing.

37. The energy storage device of claim 30, further comprising heat dissipation means, in thermal communication with said voltage conversion means, for dissipating heat generated by said voltage conversion means.

38. The energy storage device of claim 37, wherein said heat dissipation means includes a heat sink having a first surface and a second surface opposite thereof, said first surface of said heat sink is exposed to said first area of said housing, and said second surface of said heat sink is exposed to an atmosphere exterior to said housing.

39. The energy storage device of claim 38, wherein said heat sink is mounted to said cover of said housing.

40. The energy storage device of claim 39, wherein said heat dissipation means includes a second heat sink mounted to said cover of said housing, said second heat sink having a first surface and a second surface opposite thereof, said first surface of said second heat sink exposed to said first area of said housing, and said second surface of said second heat sink exposed to the atmosphere exterior to said housing.

41. An energy storage device for storing energy for starting an engine of a motor vehicle, comprising:

a DC-DC converter for converting a first voltage provided from an electrical system of the motor vehicle to a second voltage;

at least one capacitor, electrically connected to said DC-DC converter, for storing the second voltage, the second voltage providing energy for starting the engine of the motor vehicle; and

a housing for housing said DC-DC converter and said at least one capacitor, said DC-DC converter and said at least one capacitor substantially contained within said housing.

42. The energy storage device of claim 41, wherein said at least one capacitor includes a plurality of capacitors.

43. The energy storage device of claim 42, further comprising a retention structure for providing structural support to said plurality of capacitors.

44. The energy storage device of claim 43, wherein said plurality of capacitors is arranged in a first column and a second column by said retention structure.

45. The energy storage device of claim 44, wherein said retention structure includes a first structural member positioned intermediate said first and second columns, a second structural member and a third structural member, said first column being positioned intermediate said first structural member and said second structural member, and said second column being positioned intermediate said first structural member and said third structural member.

46. The energy storage device of claim 45, wherein said first structural member includes a first surface and a second surface opposite thereof, said first surface having a first plurality of recesses and said second surface having a second plurality of recesses, each of said first plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said first column, and each of said second plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said second column.

47. The energy storage device of claim 46, wherein said second structural member includes a first surface having a third plurality of recesses and said third structural member includes a first surface having a fourth plurality of recesses, each of said third plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said first column, and each of said fourth plurality of recesses is sized and shaped to receive a corresponding one of said plurality of capacitors of said second column.

48. The energy storage device of claim 47, wherein said at least one capacitor includes a second plurality of capacitors and a second retention structure for providing structural support to said second plurality of capacitors.

49. The energy storage device of claim 48, wherein said second plurality of capacitors is arranged in a first column and a second column by said second retention structure.

50. The energy storage device of claim 49, wherein said second retention structure includes a first structural member positioned intermediate said first and second columns of said second plurality of capacitors, a second structural member and a third structural member, said first column of said second plurality of capacitors being positioned intermediate said first structural member of said second retention structure and said second structural member of said second retention structure, and said second column of said second plurality of capacitors being positioned intermediate said first structural member of said second retention structure and said third structural member of said second retention structure.

51. The energy storage device of claim 50, wherein said first structural member of said second retention structure includes a first surface and a second surface opposite thereof, said first surface of said first structural member of said second retention structure having a first plurality of recesses, and said second surface of said first structural member of said second retention structure having a second plurality of recesses, each of said first plurality of recesses of said first structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said first column thereof, and each of said second plurality of recesses of said first structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said second column thereof.

52. The energy storage device of claim 51, wherein said second structural member of said second retention structure includes a first surface having a third plurality of recesses, and said third structural member of said second retention structure includes a first surface having a fourth plurality of recesses, each of said third plurality of recesses of said second structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said first column thereof, and each of said fourth plurality of recesses of said third structural member of said second retention structure is sized and shaped to receive a corresponding one of said second plurality of capacitors of said second column thereof.

53. The energy storage device of claim 52, wherein said housing includes a first area for housing said DC-DC converter and a second area for housing said first and second plurality of capacitors.

54. The energy storage device of claim 53, further comprising a barrier, positioned within said housing, for substantially separating said first and second areas of said housing from one another.

55. The energy storage device of claim 54, wherein said barrier includes a plate having a first surface and a second surface opposite thereof, said first surface of said plate being positioned within said first area of said housing, and said second surface of said plate being positioned within said second area of said housing.

56. The energy storage device of claim 55, wherein said plate is thermally insulated.

57. The energy storage device of claim 56, wherein said DC-DC converter is mounted to said first surface of said plate.

58. The energy storage device of claim 57, wherein said housing is sized and shaped substantially to that of a motor vehicle battery housing.

59. The energy storage device of claim 58, wherein said first and second plurality of capacitors includes a net positive terminal and a net negative terminal.

60. The energy storage device of claim 59, further comprising a first electrical terminal connected electrically to said net negative terminal of said first and second plurality of capacitors, a positive terminal of a motor vehicle battery, and to a starter of the motor vehicle, and a second electrical terminal connected electrically to ground.

61. The energy storage device of claim 60, wherein said first and second electrical terminals extend outwardly from said cover of said housing.

62. The energy storage device of claim 59, further comprising a first electrical terminal connected electrically to said net negative terminal of said first and second plurality of capacitors and a positive terminal of a motor vehicle battery, a second electrical terminal connected electrically to ground, and a third electrical terminal electrically connected to said net positive terminal of said first and second plurality of capacitors and to a starter of the motor vehicle.

63. The energy storage device of claim 62, wherein said first, second and third electrical terminals extend outwardly from said cover of said housing.

64. The energy storage device of claim 57, further comprising a heat sink having a first surface and a second surface opposite thereof, said first surface of said heat sink is exposed to said first area of said housing, and said second surface of said heat sink is exposed to an atmosphere exterior to said housing.

65. The energy storage device of claim 64, wherein said housing includes a first end and a cover removably mounted to said first end, said heat sink mounted to said cover of said housing.

66. The energy storage device of claim 65, further comprising a second heat sink mounted to said cover of said housing, said second heat sink having a first surface and a second surface opposite thereof, said first surface of said second heat sink exposed to said first area of said housing, and said second surface of said second heat sink exposed to the atmosphere exterior to said housing.

67. An energy storage device for storing energy for starting an engine of a motor vehicle, comprising:

a DC-DC converter for converting a first voltage generated by an electrical system of the motor vehicle to a second voltage;

a plurality of capacitors, electrically connected to said DC-DC converter, for storing the second voltage, the second voltage providing energy for starting the engine of the motor vehicle;

a housing having a first area for housing said DC-DC converter and a second area for housing said plurality of capacitors, said DC-DC converter and said plurality of capacitors are self-contained within said housing, said housing being sized and shaped substantially of that of a motor vehicle battery housing;

a thermally insulated barrier positioned between said first and second area of said housing for separating said DC-DC converter from said plurality of capacitors;

and a heat sink mounted to said housing, said heat sink being in thermal communication with said DC-DC converter for dissipating heat generated by said DC-DC converter to an atmosphere exterior to said housing.

68. An energy storage device for storing energy for supplying electric loads to transportation systems, said energy storage device comprising:

a DC-DC converter for converting a first voltage to a second voltage;

at least one ultracapacitor, electrically connected to said DC-DC converter, for storing the second voltage, the second voltage providing the energy for supplying the electric loads; and

a housing for housing said DC-DC converter and said at least one ultracapacitor, said DC-DC converter and said at least one ultracapacitor are contained substantially within said housing.

69. The energy storage device of claim 68, wherein said at least one ultracapacitor includes a plurality of ultracapacitors.

70. The energy storage device of claim 69, wherein said housing includes a first area for housing said DC-DC converter and a second area for housing said plurality of ultracapacitors.

71. The energy storage device of claim 70, further comprising a thermally insulated barrier positioned between said first and second areas of said housing for separating substantially said DC-DC converter from said plurality of ultracapacitors.

72. The energy storage device of claim 71, further comprising a heat sink mounted to said housing, said heat sink being in thermal communication with said DC-DC converter for dissipating heat generated by said DC-DC converter to an atmosphere exterior to said housing.