U.S. patent application number 13/294845 was filed with the patent office on 2012-12-27 for cooling system.
This patent application is currently assigned to DELTA ELECTRONICS (SHANGHAI) CO., LTD.. Invention is credited to Gang Liu, Peiai You, Jinfa Zhang.
Application Number | 20120325447 13/294845 |
Document ID | / |
Family ID | 45105949 |
Filed Date | 2012-12-27 |
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United States Patent
Application |
20120325447 |
Kind Code |
A1 |
You; Peiai ; et al. |
December 27, 2012 |
COOLING SYSTEM
Abstract
In one aspect of the present invention, a cooling system
includes a cooling plate having a first surface and an opposite,
second surface, a body portion defined between the first surface
and the second surface, at least one channel formed in the body
portion for a cooling fluid to flow therethrough, an inlet and an
outlet in flow communications with the at least one channel for the
cooling fluid to enter and exit the at least one channel,
respectively. The inlet and the outlet are spatially separated by a
distance. The at least one channel defines a flow path of the
cooling fluid flowing from the inlet to the outlet through the at
least one channel. The flow path has a path length substantially
greater than the distance between the inlet and the outlet.
Inventors: |
You; Peiai; (Shanghai,
CN) ; Liu; Gang; (Shanghai, CN) ; Zhang;
Jinfa; (Shanghai, CN) |
Assignee: |
DELTA ELECTRONICS (SHANGHAI) CO.,
LTD.
Shanghai
CN
|
Family ID: |
45105949 |
Appl. No.: |
13/294845 |
Filed: |
November 11, 2011 |
Current U.S.
Class: |
165/170 |
Current CPC
Class: |
H01M 10/625 20150401;
H01M 10/613 20150401; H05K 7/20927 20130101; F28F 3/12 20130101;
H01M 10/6556 20150401; Y02E 60/10 20130101; F28F 3/048
20130101 |
Class at
Publication: |
165/170 |
International
Class: |
F28F 3/14 20060101
F28F003/14 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 23, 2011 |
CN |
201110172490.X |
Claims
1. A cooling system, comprising: (a) a first cooling plate having a
first surface, an opposite, second surface, a body portion defined
between the first surface and the second surface, a concave channel
recessed from the second surface and formed in the body portion for
a cooling fluid to flow therethrough, an inlet and an outlet in
flow communications with the channel for the cooling fluid to enter
and exit the channel, respectively; and (b) a second cooling plate
having a first surface and an opposite, second surface, wherein the
second surface of the first cooling plate is adapted for mating
with the first surface of the second cooling plate such that as
assembled, the first cooling plate and the second cooling plate is
fastened together to form a sealed enclosure between the second
surface of the first cooling plate and the first surface of the
second cooling plate enclosing the channel.
2. The cooling system of claim 1, wherein the inlet is engaged with
one end of the channel and the outlet is engaged with the other end
of the channel, and wherein the inlet and the outlet are spatially
separated by a distance.
3. The cooling system of claim 2, wherein the channel is
serpentinely formed to define a zig-zag flow path of the cooling
fluid flowing from the inlet to the outlet through the channel,
wherein the zig-zag flow path has a path length substantially
greater than the distance between the inlet and the outlet.
4. The cooling system of claim 3, wherein the second cooling plate
has a fin serpentinely protruding from the first surface thereof
such that, when the first cooling plate and the second cooling
plate are fastened together, the fin is placed in the channel.
5. The cooling system of claim 1, wherein the first surface of the
second cooling plate is substantially flat.
6. The cooling system of claim 5, wherein the first cooling plate
has a fin serpentinely protruding in the channel thereof.
7. The cooling system of claim 1, wherein the first surface of the
first cooling plate is adapted for mounting at least one first
electrical component thereon.
8. The cooling system of claim 1, wherein the second surface of the
second cooling plate is adapted for mounting at least one second
electrical component thereon.
9. A cooling system, comprising: (a) a first cooling plate having a
first surface, an opposite, second surface, a body portion defined
between the first surface and the second surface, a cavity recessed
from the second surface and formed in the body portion, and a
plurality of first fins protruding from a bottom of the cavity, the
plurality of first fins being substantially parallel to each other
to form a plurality of channels therebetween for a cooling fluid to
flow therethrough, an inlet and an outlet in flow communications
with the plurality of channels for the cooling fluid to enter and
exit the plurality of channels, respectively; and (b) a second
cooling plate having a first surface and an opposite, second
surface, wherein the second surface of the first cooling plate is
adapted for mating with the first surface of the second cooling
plate such that as assembled, the first cooling plate and the
second cooling plate is fastened together to form a sealed
enclosure between the second surface of the first cooling plate and
the first surface of the second cooling plate enclosing the
cavity.
10. The cooling system of claim 9, wherein the inlet and the outlet
are spatially separated by a distance.
11. The cooling system of claim 10, wherein each of the plurality
of channels defines a respective flow path of the cooling fluid
flowing from the inlet to the outlet through the corresponding
channel, wherein the respective flow path has a path length
substantially greater than the distance between the inlet and the
outlet.
12. The cooling system of claim 10, wherein the inlet and the
outlet are placed at two diagonal corners of the cavity.
13. The cooling system of claim 9, wherein the second cooling plate
has a plurality of second fins protruding from the first surface
thereof, wherein the plurality of second fins are substantially
parallel to each other and positioned such that, when the first
cooling plate and the second cooling plate are fastened together,
the plurality of second fins inserts into the plurality of channels
formed by the plurality of first fins.
14. The cooling system of claim 9, wherein the first surface of the
second cooling plate is substantially flat.
15. The cooling system of claim 9, wherein the first surface of the
first cooling plate is adapted for mounting at least one first
electrical component thereon.
16. The cooling system of claim 9, wherein the second surface of
the second cooling plate is adapted for mounting at least one
second electrical component thereon.
17. A cooling system, comprising: a cooling plate having a first
surface and an opposite, second surface, a body portion defined
between the first surface and the second surface, at least one
channel formed in the body portion for a cooling fluid to flow
therethrough, an inlet and an outlet in flow communications with
the at least one channel for the cooling fluid to enter and exit
the at least one channel, respectively, wherein the inlet and the
outlet are spatially separated by a distance, wherein the at least
one channel defines a flow path of the cooling fluid flowing from
the inlet to the outlet through the at least one channel, and
wherein the flow path has a path length substantially greater than
the distance between the inlet and the outlet.
18. The cooling system of claim 17, wherein the at least one
channel is serpentinely formed to define a zig-zag flow path.
19. The cooling system of claim 17, further comprising a first
plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the second surface of the
first plate is substantially in contact with the first surface of
the cooling plate.
20. The cooling system of claim 19, wherein the first surface of
the first plate is adapted for mounting at least one first
electrical component thereon.
21. The cooling system of claim 20, wherein the at least one first
electrical component comprises a first power converter.
22. The cooling system of claim 17, further comprising a second
plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the first surface of the
second plate is substantially in contact with the second surface of
the cooling plate.
23. The cooling system of claim 22, wherein the second surface of
the second plate is adapted for mounting at least one second
electrical component thereon.
24. The cooling system of claim 23, wherein the at least one second
electrical component comprises a second power converter.
25. An electrical device, comprising the cooling system of claim
17.
26. The electrical device of claim 25, further comprising a first
plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the second surface of the
first plate is substantially in contact with the cooling
system.
27. The electrical device of claim 26, wherein the first surface of
the first plate is adapted for mounting at least one first
electrical component thereon.
28. The electrical device of claim 25, further comprising a second
plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the first surface of the
second plate is substantially in contact with the cooling
system.
29. The electrical device of claim 28, wherein the second surface
of the second plate is adapted for mounting at least one second
electrical component thereon.
30. The electrical device of claim 25, further comprising at least
one first electrical component and at least one second electrical
component, positioned such that the cooling system is sandwiched
between the at least one first electrical component and the at
least one second electrical component.
31. The electrical device of claim 30, wherein the at least one
first electrical component and the at least one second electrical
component are electrically connected to each other in series or in
parallel.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims priority to and the benefit of,
pursuant to 35 U.S.C. .sctn.119(a), Chinese patent application No.
201110172490.X, filed Jun. 23, 2011, entitled "COOLING SYSTEM", by
Peiai You et al., the content of which is incorporated herein by
reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a cooling system, and more
particularly, to a cooling system sandwiched between two electrical
modules.
BACKGROUND OF THE INVENTION
[0003] With the ever expanding demand for fossil fuel and
increasing awareness of the environmental impact of fossil fuel
consumption, electric and hybrid vehicles are becoming more and
more popular. The batteries used in electric or hybrid vehicles
need to be charged periodically by high frequency and high power
systems. When a battery is being charged, a significant amount of
heat is generated in the battery charging system. The generated
heat, if not properly dissipated, may cause overheating of the
electrical components in the power system, which may in turn cause
damage or deterioration of the performance of the power system.
[0004] Therefore, a heretofore unaddressed need exists in the art
to address the aforementioned deficiencies and inadequacies.
SUMMARY OF THE INVENTION
[0005] The present invention, in one aspect, relates to a cooling
system. In one embodiment, the cooling system includes a first
cooling plate having a first surface, an opposite, second surface,
a body portion defined between the first surface and the second
surface, a concave channel recessed from the second surface and
formed in the body portion for a cooling fluid to flow
therethrough, an inlet and an outlet in flow communications with
the channel for the cooling fluid to enter and exit the channel,
respectively; and a second cooling plate having a first surface and
an opposite, second surface. The second surface of the first
cooling plate is adapted for mating with the first surface of the
second cooling plate such that as assembled, the first cooling
plate and the second cooling plate is fastened together to form a
sealed enclosure between the second surface of the first cooling
plate and the first surface of the second cooling plate enclosing
the channel.
[0006] In one embodiment, the inlet is engaged with one end of the
channel and the outlet is engaged with the other end of the
channel. The inlet and the outlet are spatially separated by a
distance.
[0007] In one embodiment, the channel is serpentinely formed to
define a zig-zag flow path of the cooling fluid flowing from the
inlet to the outlet through the channel, where the zig-zag flow
path has a path length substantially greater than the distance
between the inlet and the outlet.
[0008] In one embodiment, the second cooling plate has a fin
serpentinely protruding from the first surface thereof such that,
when the first cooling plate and the second cooling plate are
fastened together, the fin is placed in the channel. In another
embodiment, the first surface of the second cooling plate is
substantially flat, where the first cooling plate has a fin
serpentinely protruding in the channel thereof.
[0009] In one embodiment, the first surface of the first cooling
plate is adapted for mounting at least one first electrical
component thereon. The second surface of the second cooling plate
is adapted for mounting at least one second electrical component
thereon.
[0010] In another aspect, the present invention relates to a
cooling system. In one embodiment, the cooling system has a first
cooling plate having a first surface, an opposite, second surface,
a body portion defined between the first surface and the second
surface, a cavity recessed from the second surface and formed in
the body portion, and a plurality of first fins protruding from a
bottom of the cavity, the plurality of first fins being
substantially parallel to each other to form a plurality of
channels therebetween for a cooling fluid to flow therethrough, an
inlet and an outlet in flow communications with the plurality of
channels for the cooling fluid to enter and exit the plurality of
channels, respectively, and a second cooling plate having a first
surface and an opposite, second surface. The second surface of the
first cooling plate is adapted for mating with the first surface of
the second cooling plate such that as assembled, the first cooling
plate and the second cooling plate is fastened together to form a
sealed enclosure between the second surface of the first cooling
plate and the first surface of the second cooling plate enclosing
the cavity.
[0011] In one embodiment, the inlet and the outlet are spatially
separated by a distance. The inlet and the outlet are placed at two
diagonal corners of the cavity.
[0012] In one embodiment, each of the plurality of channels defines
a respective flow path of the cooling fluid flowing from the inlet
to the outlet through the corresponding channel, where the
respective flow path has a path length substantially greater than
the distance between the inlet and the outlet.
[0013] In one embodiment, the second cooling plate has a plurality
of second fins protruding from the first surface thereof, where the
plurality of second fins are substantially parallel to each other
and positioned such that, when the first cooling plate and the
second cooling plate are fastened together, the plurality of second
fins inserts into the plurality of channels formed by the plurality
of first fins.
[0014] In another embodiment, the first surface of the second
cooling plate is substantially flat.
[0015] In one embodiment, the first surface of the first cooling
plate is adapted for mounting at least one first electrical
component thereon. The second surface of the second cooling plate
is adapted for mounting at least one second electrical component
thereon.
[0016] In yet another aspect, the present invention relates to a
cooling system. In one embodiment, the cooling system a cooling
plate having a first surface and an opposite, second surface, a
body portion defined between the first surface and the second
surface, at least one channel formed in the body portion for a
cooling fluid to flow therethrough, an inlet and an outlet in flow
communications with the at least one channel for the cooling fluid
to enter and exit the at least one channel, respectively. The inlet
and the outlet are spatially separated by a distance. The at least
one channel defines a flow path of the cooling fluid flowing from
the inlet to the outlet through the at least one channel. The flow
path has a path length substantially greater than the distance
between the inlet and the outlet.
[0017] In one embodiment, the at least one channel is serpentinely
formed to define a zig-zag flow path.
[0018] The cooling system may further have a first plate having a
first surface and an opposite, second surface, attached to the
cooling plate such that the second surface of the first plate is
substantially in contact with the first surface of the cooling
plate. In one embodiment, the first surface of the first plate is
adapted for mounting at least one first electrical component
thereon, where the at least one first electrical component
comprises a first power converter.
[0019] Additionally, the cooling system may also have a second
plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the first surface of the
second plate is substantially in contact with the second surface of
the cooling plate. In one embodiment, the second surface of the
second plate is adapted for mounting at least one second electrical
component thereon, where the at least one second electrical
component comprises a second power converter.
[0020] In a further aspect, the present invention relates to an
electrical device comprising the cooling system as disclosed
above.
[0021] In one embodiment, the electrical device further has a first
plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the second surface of the
first plate is substantially in contact with the cooling system,
wherein the first surface of the first plate is adapted for
mounting at least one first electrical component thereon.
[0022] In another embodiment, the electrical device may have a
second plate having a first surface and an opposite, second
surface, attached to the cooling plate such that the first surface
of the second plate is substantially in contact with the cooling
system, where the second surface of the second plate is adapted for
mounting at least one second electrical component thereon.
[0023] In one embodiment, the electrical device may have at least
one first electrical component and at least one second electrical
component, positioned such that the cooling system is sandwiched
between the at least one first electrical component and the at
least one second electrical component, where the at least one first
electrical component and the at least one second electrical
component are electrically connected to each other in series or in
parallel.
[0024] These and other aspects of the present invention will become
apparent from the following description of the preferred embodiment
taken in conjunction with the following drawings, although
variations and modifications therein may be effected without
departing from the spirit and scope of the novel concepts of the
disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings illustrate one or more embodiments
of the invention and together with the written description, serve
to explain the principles of the invention. Wherever possible, the
same reference numbers are used throughout the drawings to refer to
the same or like elements of an embodiment, and wherein:
[0026] FIG. 1 shows an exploded perspective view of an electrical
device, such as a battery charging system, that includes a cooling
system, according to one embodiment of the present invention;
[0027] FIG. 2 shows a perspective view of a first cooling plate in
the battery charging system shown in FIG. 1, according to one
embodiment of the present invention;
[0028] FIG. 3 shows a perspective view of a second cooling plate in
the battery charging system shown in FIG. 1, according to one
embodiment of the present invention;
[0029] FIG. 4 shows a cutaway perspective view when coupling the
first cooling plate to the second cooling plate of the cooling
system in the battery charging system shown in FIG. 1, according to
one embodiment of the present invention;
[0030] FIG. 5 shows a perspective view of the battery charging
system shown in FIG. 1 as assembled;
[0031] FIG. 6 shows a cutaway perspective view when coupling the
first cooling plate to the second cooling plate of the cooling
system in the battery charging system shown in FIG. 1, according to
another embodiment of the present invention;
[0032] FIG. 7 shows an exploded perspective view of an electrical
device, such as a battery charging system, that includes a cooling
system, according to another embodiment of the present invention;
and
[0033] FIG. 8 shows a perspective view of the battery charging
system shown in FIG. 7 as assembled.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The present invention will now be described more fully
hereinafter with reference to the accompanying drawings, in which
exemplary embodiments of the invention are shown. This invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Like reference numerals
refer to like elements throughout.
[0035] It will be understood that when an element is referred to as
being "on" another element, it can be directly on the other element
or intervening elements may be present therebetween. In contrast,
when an element is referred to as being "directly on" another
element, there are no intervening elements present. As used herein,
the term "and/or" includes any and all combinations of one or more
of the associated listed items.
[0036] It will be understood that, although the terms first,
second, third, etc. may be used herein to describe various
elements, components, regions, layers and/or sections, these
elements, components, regions, layers and/or sections should not be
limited by these terms. These terms are only used to distinguish
one element, component, region, layer or section from another
element, component, region, layer or section. Thus, a first
element, component, region, layer or section discussed below could
be termed a second element, component, region, layer or section
without departing from the teachings of the present invention.
[0037] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," or "includes"
and/or "including" or "has" and/or "having" when used herein,
specify the presence of stated features, regions, integers, steps,
operations, elements, and/or components, but do not preclude the
presence or addition of one or more other features, regions,
integers, steps, operations, elements, components, and/or groups
thereof.
[0038] Furthermore, relative terms, such as "lower" or "bottom",
"upper" or "top," and "front" or "back" may be used herein to
describe one element's relationship to another element as
illustrated in the figures. It will be understood that relative
terms are intended to encompass different orientations of the
device in addition to the orientation depicted in the figures. For
example, if the device in one of the figures is turned over,
elements described as being on the "lower" side of other elements
would then be oriented on "upper" sides of the other elements. The
exemplary term "lower", can therefore, encompasses both an
orientation of "lower" and "upper," depending of the particular
orientation of the figure. Similarly, if the device in one of the
figures is turned over, elements described as "below" or "beneath"
other elements would then be oriented "above" the other elements.
The exemplary terms "below" or "beneath" can, therefore, encompass
both an orientation of above and below.
[0039] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and the present
disclosure, and will not be interpreted in an idealized or overly
formal sense unless expressly so defined herein.
[0040] As used herein, "around", "about" or "approximately" shall
generally mean within 20 percent, preferably within 10 percent, and
more preferably within 5 percent of a given value or range.
Numerical quantities given herein are approximate, meaning that the
term "around", "about" or "approximately" can be inferred if not
expressly stated.
[0041] As used herein, the term "plurality" means a number greater
than one.
[0042] The description will be made as to the embodiments of the
present invention in conjunction with the accompanying drawings in
FIGS. 1-8. In accordance with the purposes of this invention, as
embodied and broadly described herein, this invention, in one
aspect, relates to a cooling system useable for an electrical
device, such as a battery charging system.
[0043] FIG. 1 shows an exploded perspective view of a battery
charging system 100 that includes a cooling system, according to
one embodiment of the present invention. As shown in FIG. 1, the
cooling system in the exemplary embodiment includes a first cooling
plate 110 and a second cooling plate 120. Referring to FIGS. 1, 2
and 4 and particularly to FIG. 2, the first cooling plate 110 has a
first surface 112, an opposite, second surface 114, a body portion
113 defined between the first surface 112 and the second surface
114, a plurality of fins 117 protruded from the bottom of the base
of the body portion 113, so a concave channel 116 recessed from the
second surface 114 and formed in the body portion for a cooling
fluid to flow therethrough, an inlet 118a and an outlet 118b in
flow communications with the channel 116 for the cooling fluid to
enter and exit the channel 116, respectively. The inlet 118a is
engaged with one end of the channel 116 and the outlet 118b is
engaged with the other end of the channel 116. The inlet 118a and
the outlet 118b are spatially separated by a distance. The channel
116 is serpentinely formed to define a zig-zag flow path of the
cooling fluid flowing from the inlet 118a to the outlet 118b
through the channel 116, where the zig-zag flow path has a path
length substantially greater than the distance between the inlet
118a and the outlet 118b.
[0044] Referring to FIGS. 1, 3 and 4 and particularly to FIG. 3,
the second cooling plate 120 has a first surface 122 and an
opposite, second surface 124. The second cooling plate 120 has a
fin 126 serpentinely protruding from the first surface 122
thereof.
[0045] The second surface 114 of the first cooling plate 110 is
adapted for mating with the first surface 122 of the second cooling
plate 120 such that as assembled, the first cooling plate 110 and
the second cooling plate 120 is fastened together to form a sealed
enclosure between the second surface 114 of the first cooling plate
110 and the first surface 122 of the second cooling plate 120
enclosing the channel 116. FIG. 4 shows a cutaway perspective view
when coupling the first cooling plate 110 to the second cooling
plate 120 of the cooling system 100 in the battery charging system
shown in FIG. 1, according to one embodiment of the present
invention. From the cutaway perspective view as shown in FIG. 4,
when coupling the first cooling plate 110 to the second cooling
plate 120, the fin 126 protruding from the first surface 122 of the
second cooling plate 120 is placed in the channel 116 formed in the
first cooling plate 110.
[0046] In an alternative embodiment (not shown), the first surface
of the second cooling plate is substantially flat, while the first
cooling plate 110 have a plurality of fins 117 serpentinely
protruding in the channel 116 thereof.
[0047] As shown in FIG. 1, the battery charging system 100 includes
a first power converter 130 and a second power converter 132,
mounted on the first surface 112 of the first cooling plate 110 and
the second surface 124 of the second cooling plate 120,
respectively. In one embodiment, each of the first power converter
130 and the second power converter 132 is a high frequency power
converter and outputs approximately 3.3 kW power. The first power
converter 130 and the second power converter 132 may be connected
to each other in series or in parallel to produce a total power of
approximately 6.6 kW. The battery charging system 100 also includes
a first cover plate 150 for enclosing the first power converter
130, and a second cover plate 160 for enclosing the second power
converter 132.
[0048] FIG. 5 shows a perspective view of the assembled battery
charging system 100. In operation, a cooling fluid flowing through
the channel 116 carries away the heat generated by the first power
converter 130 and the second power converter 132. Because the
cooling system is sandwiched between the first power converter 130
and the second power converter 132, the battery charging system 100
is compact and the cooling is efficient.
[0049] FIG. 6 shows a cutaway perspective view when coupling the
first cooling plate to the second cooling plate of the cooling
system in the battery charging system shown in FIG. 1, according to
another embodiment of the present invention. In this embodiment,
the first cooling plate 110' has a cavity 115 recessed from the
second surface 114 and formed in the body portion 113 thereof. A
plurality of first parallel fins 601 is protruded from a bottom of
the cavity 115. The second cooling plate (not shown) also has a
plurality of second parallel fins protruding from the second
surface 124 thereof. When the first cooling plate 110' and the
second cooling plate are coupled together, the plurality of the
second parallel fins are placed between the plurality of the first
parallel fins 601 to form a plurality of channels 119 therebetween
for a cooling fluid to flow therethrough. The first cooling plate
110' also has an inlet 118a' and an outlet 118b' in flow
communications with the plurality of channels 119 for the cooling
fluid to enter and exit the plurality of channels 119,
respectively. The inlet 118a' and the outlet 118b' are spatially
separated by a distance. In the example, the inlet 118a' and the
outlet 118b' are positioned at two diagonal corners of the cavity
115.
[0050] Each of the plurality of channels 119 defines a respective
flow path of the cooling fluid flowing from the inlet 118a' to the
outlet 118b' through the corresponding channel, where the
respective flow path has a path length substantially greater than
the distance between the inlet 118a' and the outlet 118b'.
[0051] In this embodiment, the cooling fluid flows the plurality of
channels 119 in the same direction, which reduces the pressure drop
of the cooling fluid from the inlet 118a' to the outlet 118b'.
[0052] In an alternative embodiment, the second surface of the
second cooling plate is substantially flat. So a plurality of
channels is formed between the plurality of the first parallel fins
601 for a cooling fluid to flow therethrough.
[0053] FIG. 7 shows an exploded perspective view of a battery
charging system 700 that includes a cooling system, according to
another embodiment of the present invention. The battery charging
system 700 includes a first cooling plate 710, a second cooling
plate 720, and a third cooling plate 730. The first cooling plate
has a first surface 712 and an opposite, second surface 714. The
second cooling plate has a first surface 722 and an opposite,
second surface 724. The third cooling plate has a first surface 732
and an opposite, second surface 734. The battery charging system
700 further includes a first power converter 740 mounted on the
first surface 712 of the first cooling plate 710, and a second
power converter 750 mounted on the second surface 734 of the third
cooling plate 730.
[0054] In one embodiment, each of the first power converter 740 and
the second power converter 750 is a high frequency power converter
and outputs approximately 3.3 kW power. The first power converter
740 and the second power converter 750 may be connected to each
other in series or in parallel to produce a total power of
approximately 6.6 kW. The battery charging system 700 further
includes a first cover 760 for enclosing the first power converter
740, and a second cover 770 for enclosing the second power
converter 750.
[0055] The second cooling plate 720 is sandwiched between the first
cooling plate 710 and the third cooling plate 730, and has a
concave channel 726 formed on the first surface 722 thereof for a
cooling fluid to flow therethrough. The first surface 722 of the
second cooling plate 720 is adapted for mating with the second
surface 714 of the first cooling plate 710 such that the first
cooling plate 710 and the second cooling plate 720 can be fastened
together to form a sealed enclosure between the second surface 714
of the first cooling plate 710 and the first surface 722 of the
second cooling plate 720 enclosing the channel 726. The second
cooling plate 720 further has an inlet 728a and an outlet 728b in
flow communication with the channel 726 for the cooling fluid to
enter and exit the channel 726, respectively. The channel 726 has a
zig-zag contour covering a majority area of the first surface 722
of the second cooling plate 720. Each of the second surface 724 of
the second cooling plate 720 and the first surface 732 of the third
cooling plate 730 is substantially flat so that, when the second
cooling plate 720 and the third cooling plate 730 are fastened
together, the third cooling plate 730 is in good thermal contact
with the second cooling plate 720.
[0056] In other embodiment, the second surface 724 can also have a
concave channel for a cooling fluid to flow therethrough.
[0057] FIG. 8 shows a perspective view of the battery charging
system 700 when assembled. The first cooling plate 710, the second
cooling plate 720, and the third cooling plate 730 can be fastened
together using screws, bolts, or other fastening means. In
operation, a cooling fluid that flows through the channel 726 in
the second cooling plate 720 carries away the heat generated by the
first power converter 740 and the second power converter 750.
Because the cooling system is sandwiched between the first power
converter 740 and the second power converter 750, the battery
charging system 700 is compact and the cooling is efficient.
[0058] Generally, the present invention relates to a cooling system
that includes a cooling plate having a first surface and an
opposite, second surface, a body portion defined between the first
surface and the second surface, at least one channel formed in the
body portion for a cooling fluid to flow therethrough, an inlet and
an outlet in flow communications with the at least one channel for
the cooling fluid to enter and exit the at least one channel,
respectively. The inlet and the outlet are spatially separated by a
distance. The at least one channel defines a flow path of the
cooling fluid flowing from the inlet to the outlet through the at
least one channel. The flow path has a path length substantially
greater than the distance between the inlet and the outlet. The at
least one channel can be formed serpentinely to define a zig-zag
flow path.
[0059] The cooling system may further have a first plate having a
first surface and an opposite, second surface, attached to the
cooling plate such that the second surface of the first plate is
substantially in contact with the first surface of the cooling
plate. Additionally, the cooling system may also have a second
plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the first surface of the
second plate is substantially in contact with the second surface of
the cooling plate.
[0060] Although the cooling system in its various embodiments is
described above in the context of a battery charging system, it is
understood that the cooling system can be used for other electrical
systems that generate a significant amount of heat. The cooling
system may be sandwiched between two modules of an electrical
system, each module comprising one or more electrical components,
such as switches, inductors, or capacitors. The electrical
components may be mounted on, for example and without limitation, a
printed circuit board (PCB). In other embodiment, there can be more
than one cooling system, and one of them been sandwiched between
two modules of an electrical system.
[0061] In one aspect of the present invention, an electrical device
such as a battery charging system includes the cooling system as
disclosed above.
[0062] In one embodiment, the electrical device also includes a
first plate having a first surface and an opposite, second surface,
attached to the cooling plate such that the second surface of the
first plate is substantially in contact with the cooling system,
where the first surface of the first plate is adapted for mounting
at least one first electrical component thereon. The electrical
device may further have a second plate having a first surface and
an opposite, second surface, attached to the cooling plate such
that the first surface of the second plate is substantially in
contact with the cooling system, where the second surface of the
second plate is adapted for mounting at least one second electrical
component thereon. For example, the at least one first electrical
component comprises a first power converter, while the at least one
second electrical component comprises a second power converter
[0063] In another embodiment, the electrical device may have at
least one first electrical component and at least one second
electrical component, positioned such that the cooling system is
sandwiched between the at least one first electrical component and
the at least one second electrical component, where the at least
one first electrical component and the at least one second
electrical component are electrically connected to each other in
series or in parallel.
[0064] The foregoing description of the exemplary embodiments of
the invention has been presented only for the purposes of
illustration and description and is not intended to be exhaustive
or to limit the invention to the precise forms disclosed. Many
modifications and variations are possible in light of the above
teaching.
[0065] The embodiments were chosen and described in order to
explain the principles of the invention and their practical
application so as to activate others skilled in the art to utilize
the invention and various embodiments and with various
modifications as are suited to the particular use contemplated.
Alternative embodiments will become apparent to those skilled in
the art to which the present invention pertains without departing
from its spirit and scope. Accordingly, the scope of the present
invention is defined by the appended claims rather than the
foregoing description and the exemplary embodiments described
therein.
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