Energy storage device for starting engines of motor vehicles and other transportation systems

• US 8,134,343 B2
• Filed: 03/18/2008
• Issued: 03/13/2012
• 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., Coulter, Christopher, York, Michael T.
• Primary Examiner(s): WILLIAMS, ARUN C
• Application Number:
  US12/050,615
• Publication Number:
  US 20080265586A1
• Time in Patent Office: 1,456 Days
• Field of Search: 320/166
• US Class Current: 320/166
• 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 use in connection with an independently-operable engine of a motor vehicle, the engine including a battery and an engine starter, the energy storage device comprising:

a DC-DC converter for converting a first voltage provided from the battery 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;

a portable 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 portable housing, wherein said energy storage device is separate from and selectively coupleable to said independently-operable engine wherein said housing includes a first area for housing said DC-DC converter and a second area for housing a first and second plurality of capacitors;

a barrier, positioned within said housing, for substantially separating said first and second areas of said housing from one another, said barrier includes a thermally insulated 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, said DC-DC converter is mounted to said first surface of said plate; and

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.

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

3. The energy storage device of claim 2, further comprising a retention structure for providing structural support to said plurality of capacitors.

4. The energy storage device of claim 3, wherein said plurality of capacitors is arranged in a first column and a second column by said retention structure.

5. The energy storage device of claim 4, 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.

6. The energy storage device of claim 5, 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.

7. The energy storage device of claim 6, 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.

8. The energy storage device of claim 7, 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.

9. The energy storage device of claim 8, wherein said second plurality of capacitors is arranged in a first column and a second column by said second retention structure.

10. The energy storage device of claim 9, 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.

11. The energy storage device of claim 10, 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.

12. The energy storage device of claim 11, 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.

13. The energy storage device of claim 1, wherein said housing is sized and shaped substantially to that of a motor vehicle battery housing.

14. The energy storage device of claim 13, wherein said first and second plurality of capacitors includes a net positive terminal and a net negative terminal.

15. The energy storage device of claim 14, 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.

16. The energy storage device of claim 15, wherein said first, second and third electrical terminals extend outwardly from said cover of said housing.

17. The energy storage device of claim 1, 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.

18. 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.