Packaging method for modular power cells

• US 7,798,892 B2
• Filed: 08/31/2006
• Issued: 09/21/2010
• Est. Priority Date: 08/31/2005
• Status: Active Grant

• Current Assignee: Innomotics GmbH (Siemens AG)
• Original Assignee: Siemens Industry Incorporated (Siemens AG)
• Inventors: Jordan, Wayne Sheldon, Cheesman, Edward Alan, Aiello, Marc F.
• Primary Examiner(s): McAllister; Steven B
• Assistant Examiner(s): OREILLY, PATRICK F
• Application Number:
  US11/515,294
• Publication Number:
  US 20070048561A1
• Time in Patent Office: 1,482 Days
• Field of Search: 454/184, 361/696, 361/679.47
• 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:

providing at least one power cell electrically connected between a transformer and an electrical load being served;

providing the power cell with one or more power connectors electrically connected to a backplane of a power cell system enclosure;

directing air into the power cell to cool a first area of 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;

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

directing water through a water intake to a water-cooled heat sink located proximate, and operably coupled to, a transistor module in a second area of the power cell to cool the second area of the cell, the transistor module being electrically connected to the one or more power connectors of the power cell via one or more busses;

receiving water from a water output, wherein water expelled through the water output is warmer than water directed into the water intake; and

cooling the water 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, 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 the water intake and the water output.

5. The method of claim 1, wherein:

the cell comprises an air intake, an air output, 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:

providing at least one of the plurality of power cells electrically connected between a transformer and an electrical load being served;

directing air into the plurality of power cells, wherein each cell comprises an air intake, an air output, a water-cooled heat sink located proximate and operably coupled to, a transistor module in a back area of the cell, and a plurality of capacitor connectors located in a front area of the cell, wherein the directing comprises directing the air through the air intake of each cell such that the air cools the capacitor connectors;

passing the air over the water-cooled heat sink 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;

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

directing water through a water intake to the heat sink of each cell and receiving water from a water output such that the water in each heat sink cools the transistor module of its associated cell; and

cooling the water 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.