Cold plate incorporating S cell

Abstract

To improve cooling of a power electronics device while maintaining a compact package size.SOLUTION: A power electronics system including a power electronics device assembly having a cold plate is disclosed. The cold plate includes an S cell with a body of graphite or graphite composite material. The body defines a recess for a power device. The S cell is placed within the cavity of the cold plate. The cold plate further includes a bonding material bonding the S cell to the base wall of the cavity.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present specification relates generally to power electronic assemblies, and more particularly to cooling arrangements for power electronic assemblies. [Background technology]

[0002] The increasing use of electronics in automobiles requires that electronic systems be made more compact. One component of such electronic systems is the power electronics device, which is used as a switch in the inverter. Power electronics devices generate heat and therefore have high cooling requirements.

[0003] Additionally, power electronic devices traditionally constructed from silicon are now increasingly constructed from silicon carbide, which reduces the footprint of the device and therefore increases the heat flux, creating a need for improved cooling of power electronic devices while maintaining a compact package size. Summary of the Invention

[0004] In one aspect, the cold plate includes an S-cell having a body of graphite or graphite composite material, the body defining a recess for the power device, the S-cell disposed within a cavity in the cold plate, and the cold plate further includes a bonding material bonding the S-cell to a base wall of the cavity.

[0005] In another aspect, a power electronic device assembly includes a cold plate defining a cavity and a power electronic device. The cold plate includes an S-cell disposed within the cavity of the cold plate. The S-cell has a body including graphite or a graphite composite material. The body defines a power device recess. The cold plate further includes a bonding material bonding the S-cell to a base wall of the cavity. The power electronic device is embedded within the power device recess of the S-cell.

[0006] In yet another aspect, a power electronics system includes a circuit board assembly and a power electronics device assembly coupled to the circuit board assembly. The power electronics device assembly includes a cold plate defining a cavity and a power electronics device. The cold plate includes an S-cell disposed within the cavity of the cold plate. The S-cell has a body including graphite or a graphite composite material. The body defines a recess for the power device. The cold plate also includes a bonding material bonding the S-cell to a base wall of the cavity. The power electronics device is embedded within the power device recess of the S-cell.

[0007] These and additional features provided by the aspects and embodiments described herein will be more fully understood by considering the following detailed description in conjunction with the drawings. [Brief description of the drawings]

[0008] The aspects and embodiments set forth in the drawings are exemplary and explanatory in nature and are not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments, in which like structure is indicated with like reference numerals, can be understood when read in conjunction with the following drawings, in which: [Figure 1]FIG. 1 is a schematic perspective view of an exemplary power electronics system according to one or more embodiments described and illustrated herein. [Diagram 2] FIG. 2 is a schematic exploded perspective view of the power electronics system illustrated in FIG. 1 according to one or more embodiments described and illustrated herein. [Diagram 3] FIG. 3 is a schematic cross-sectional view of an exemplary power electronics system according to one or more embodiments described and illustrated herein. [Figure 4] FIG. 4 is a schematic cross-sectional view of an exemplary S-cell according to one or more embodiments described and illustrated herein. [Diagram 5] FIG. 5 is a schematic perspective view of the S-cell illustrated in FIG. 4 according to one or more embodiments described and illustrated herein. [Figure 6] FIG. 6 is a schematic top perspective view of an exemplary cold plate having multiple S-cells embedded therein according to one or more embodiments described and illustrated herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] The embodiments described herein are generally directed to a power electronics system having a circuit board assembly coupled to a power electronics device assembly including a cold plate containing an S-cell. The power electronics device may be embedded within the S-cell and / or within the circuit board assembly. The S-cell is specifically sized and shaped to ensure a particular thermal conductivity for transferring heat generated in the power electronics device.

[0010] The power electronics device assembly of the present disclosure includes a power electronics device affixed to a mounting substrate, referred to herein as an S-cell. As described in more detail below, the S-cell includes an electrical insulation layer that electrically insulates a bottom electrode of the power electronics device from other components of the power electronics device assembly. For example, the integral electrical insulation layer of the S-cell allows for the elimination of an electrical insulation layer between a printed circuit board and a cold plate, since electrical insulation is provided by the S-cell itself.

[0011] As described in more detail below, the S-cells of the present disclosure provide enhanced heat dissipation characteristics due to the graphite layer that promotes the flow of heat flux toward the cold plate. The S-cells described herein include laminated metal, graphite, and one or more electrical insulation layers in a compact package. Because the graphite of the S-cells described herein does not have an isothermal profile, the S-cells described herein are specifically shaped and sized to ensure proper heat spreading. More specifically, the portions of the S-cells that extend along two axes may define regions of high thermal conductivity relative to the portions of the S-cells that extend along a third axis that has a relatively low thermal conductivity. The resulting shape of the S-cells (e.g., rectangular shape) may allow heat to spread along the axis of high thermal conductivity rather than the axis of low thermal conductivity, thereby improving the overall spread of heat within the S-cell and / or reducing the spread of heat to adjacent S-cells, thereby avoiding the problem of centralized S-cells overheating in power electronics systems.

[0012] The cold plates, power electronics device assemblies, circuit board assemblies, power electronics systems, etc. described herein may be used in, but are not limited to, motorized vehicles such as electric vehicles and hybrid electric vehicles, any electric motor, generators, industrial tools, household appliances, etc. The various assemblies described herein may be configured as inverter circuits that may be electrically coupled to an electric motor and / or a battery and operable to convert direct current (DC) power to alternating current (AC) power.

[0013] As used herein, "power electronic device" refers to any electrical component used to convert direct current power to alternating current power and vice versa. Embodiments may also be used in AC-AC and DC-DC converter applications. Non-limiting examples of power electronic devices include metal oxide semiconductor field effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), thyristors, and power transistors.

[0014] As used herein, the term "fully embedded" means that each surface of the component is surrounded by the substrate. For example, if a power electronics device assembly is fully embedded by a circuit board substrate, it means that the material of the circuit board substrate covers each surface of the circuit board substrate. If one or more surfaces of the component are exposed, the component is "partially embedded."

[0015] As used herein, an "S-cell" is a mounting substrate that is inserted into a cavity in a cold plate and is operable to fasten a power electronic device and includes one or more of a metal layer, a graphite layer, and an electrical insulating layer.

[0016] Various embodiments of the power electronics device assembly, the power electronics system, and the cold plate are described in detail below. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like parts.

[0017] 1 and 2, an exemplary power electronics system 100 is illustrated in assembled and exploded views, respectively. The power electronics system 100 illustrated by FIG. 1 and FIG. 2 includes a cold plate 102 and a circuit board assembly 106. Although not shown in FIG. 1 and FIG. 2, in some embodiments, a bonding layer, or a thermal grease layer, may be disposed between the cold plate 102 and the circuit board assembly 106. The cold plate 102 may be any device capable of removing heat flux from a power electronic device 140 (see FIG. 3) that is bonded or embedded in a cavity 103 of the cold plate 102 and / or bonded or embedded in a substrate material of the circuit board assembly 106. Non-limiting examples of cold plates include heat sinks, single-phase liquid cooling, two-phase liquid cooling, and vapor chambers. FIG. 1 and FIG. 2 illustrate the cold plate 102 configured as a single-phase liquid cooling device. The cold plate 102 includes a fluid inlet 132 and a fluid outlet 134 fluidly coupled to a fluid chamber 115 within the cold plate 102. Although the fluid inlet 132 and the fluid outlet 134 are illustrated on the same side of the cold plate 102 in FIGS. 1 and 2, the present disclosure is not limited to such embodiments. That is, in other embodiments, the fluid inlet 132 and the fluid outlet 134 may be located on other surfaces. For example, in FIG. 6, the fluid inlet 132 is illustrated on a first surface and the fluid outlet 134 is illustrated on a second surface opposite the first surface. With brief reference to FIG. 3, coolant (depicted as moving arrows 135) from a reservoir (not shown) flows into the fluid chamber 115 through the fluid inlet 132, flows out of the fluid chamber 115 through the fluid outlet 134, and is returned to the reservoir, such as after passing through a heat exchanger (not shown) to remove heat from the coolant. Although not shown, fins may be arranged in the fluid chamber 115 to provide additional surface area for heat transfer to the cooling fluid 135 .

[0018] 1 and 2, the circuit board assembly 106 is coupled (e.g., affixed) to the first surface 107 of the cold plate 102. FIGS. 1 and 2 show the circuit board assembly 106 being affixed to the first surface 107 of the cold plate 102 by fasteners 101 (e.g., bolts and nuts) disposed through through holes 105 in the cold plate 102 and through holes 109 in the circuit board assembly 106. When fasteners 101 are used, the bonding layer disposed between the cold plate 102 and the circuit board assembly 106 may be a thermal grease layer to reduce the thermal resistance between the circuit board assembly 106 and the cold plate 102. It should be noted that such a bonding layer configured as thermal grease does not have a dedicated through hole. It should be understood that the embodiment shown in FIGS. 1 and 2 may be particularly used when additional electrical components 130 (see FIG. 3) are coupled to the cold plate 102. If such components are not included, as described below, the through holes 105, 109 and fasteners 101 may be omitted.

[0019] In other embodiments, the circuit board assembly 106 is coupled (e.g., affixed) to the first surface 107 of the cold plate 102 by a bonding layer 104 configured as a solder layer and disposed therebetween. For example, a bottom surface of the circuit board assembly 106 may include a metal layer that enables the circuit board assembly 106 to be coupled (e.g., affixed) to the first surface 107 of the cold plate 102 by a solder layer. Other bonding methods may also be utilized without departing from the scope of the present disclosure.

[0020] In yet other embodiments, the circuit board assembly 106 may be a 3D printed layer that is 3D printed directly onto the cold plate 102 (e.g., 3D printed onto the first surface 107 of the cold plate 102). In such embodiments, it should be appreciated that the 3D printed layer of the circuit board assembly 106 reduces the overall thermal resistance. Other additive manufacturing processes for attaching the circuit board assembly 106 to the cold plate 102 are also contemplated and are within the scope of the present disclosure.

[0021] In yet another embodiment, the circuit board assembly 106 may be laminated to the first surface 107 of the cold plate 102. Additionally, via connections may be made between various components of the circuit board assembly 106 and the power electronic device assembly 120 (FIG. 3) using a laser drilling process, i.e., vias are drilled through the laminated circuit board assembly 106 to the top surface of each conductive layer and to the power devices of the power electronic device assembly 120. The vias are then filled with copper by electroplating to establish electrical connections between the components.

[0022] 3, a cross-sectional view of an exemplary power electronics system 100 is illustrated. In the illustrated embodiment, an additional electrical component 130 is coupled (attached) to a second surface of the cold plate 102. As a non-limiting example, the additional electrical component 130 may be, for example, a capacitor of an inverter circuit. It should be understood that in other embodiments, the additional electrical component 130 may not be attached to the cold plate 102.

[0023] The circuit board assembly 106 includes a substrate 111 made of an electrically insulating material. The electrically insulating material may be a material used in the manufacture of printed circuit boards, such as, but not limited to, FR-4. The circuit board assembly 106 further includes an embedded conductive layer 110 and a number of vias 112 (both conductive and thermal vias). In some embodiments, the circuit board assembly 106 may also include a number of power electronic device assemblies 120 embedded fully or partially therein. However, the embodiment shown in FIG. 3 shows the power electronic device assemblies 120 embedded within S-cells 121 that are disposed within cavities 103 of the cold plate 102, as described in more detail herein.

[0024] As a non-limiting example, the cold plate 102 may include six cavities 103 therein for receiving six S cells 121 and six power electronic device assemblies 120 for an inverter circuit for an electric vehicle. However, it should be understood that any number of S cells and power electronic device assemblies may be utilized depending on the application.

[0025] Each power electronic device assembly 120 includes an S-cell 121 received in a cavity 103 of the cold plate 102 and a power electronic device 140 bonded (attached) to the S-cell 121. As described above, the S-cell 121 is the substrate to which the power electronic device 140 is bonded. The S-cell 121 provides an electrically conductive surface area for connection to an electrode on the bottom side of the power electronic device 140. The S-cell 121 further provides a heat spreading function as well as electrical insulation. However, in some embodiments, as described in more detail herein, an additional electrical insulation layer 180 can be interposed between the S-cell 121 and the base wall 104 of the cavity 103 of the cold plate 102 to provide additional electrical insulation.

[0026] As a non-limiting example, the S-cells 121 may be arranged in each of the six cavities 103 of the cold plate, for a total of six S-cells 121. Furthermore, the power electronic device assemblies 120 may be embedded in each of the six S-cells 121, for a total of six power electronic device assemblies 120. In a conventional arrangement, the shape and size of the conventional S-cells results in uniform heat diffusion from each of the S-cells, which results in heat diffusion between the S-cells, especially in the centrally located S-cell, thereby reducing the overall cooling performance of the cold plate. Therefore, the S-cells 121 of the present disclosure are specifically shaped and sized to orient the heat flux in a direction that avoids heat diffusion to adjacent S-cells, as described below.

[0027] 4 and 5 are cross-sectional and top perspective views, respectively, of an exemplary S-cell 121. The S-cell 121 includes a body 131 formed from a plurality of stacked layers. In particular, the S-cell 121 shown in FIGS. 4 and 5 includes a body 131 including a first metal layer 122, a graphite layer 124, and a second metal layer 126. The second metal layer 126 includes a first surface 125 facing the graphite layer and a second surface 128 opposite the first surface 125, the second surface 128 having a recess 127 dimensioned to receive a power electronic device 140 therein. As shown in FIGS. 4 and 5, the first and second metal layers 122, 126 at least partially surround the graphite layer 124. As used herein, the term "graphite composite" is meant to encompass structures in which graphite is at least partially surrounded by metal, as shown in FIGS. 4 and 5 and described in more detail herein below. As described in more detail below, the second metal layer 126 provides a conductive surface to which conductive vias may contact to make electrical connection to electrodes on the bottom surface of the power electronic device 140. It should be understood that the various layers of the S-cell 121 shown in Figures 4 and 5 are merely exemplary. That is, for example, the S-cell 121 may have one or more graphite layers at least partially surrounded by a metal portion (e.g., one or more metal layers, a metal shell, a metal casing, etc.). In a further example, the S-cell 121 may include one or more graphite layers that are completely surrounded by a metal portion such that the metal portion encapsulates the one or more graphite layers therein. Any of these examples are encompassed by the term "graphite composite" as used herein.

[0028] As a non-limiting example, the layers of the S-cells may be joined together by a high-temperature active metal brazing method to form bonding layers 129 (i.e., active metal brazing layers). However, it should be understood that the various layers may be joined using other known and yet to be developed techniques.

[0029] It should be noted that the illustrated S-cell 121 in the embodiment of Figures 4 and 5 includes a graphite layer 124 and a pair of metal layers (i.e., a first metal layer 122 and a second metal layer 126), providing an S-cell 121 that is symmetrical along the Z-axis shown in Figure 5. The symmetry of the S-cell 121 balances the forces on the S-cell during the high-temperature bonding process. Because the first and second metal layers 122, 126 and the graphite layer 124 have different thermal expansion coefficients, a symmetrical substrate stack may be desirable to balance thermally induced stresses during the bonding process.

[0030] The first and second metal layers 122, 126 can be made of any suitable metal or alloy. Copper and aluminum can be used as the first and second metal layers 122, 126, as non-limiting examples. It should be further understood that the metal portions used to at least partially or completely surround the graphite layers described herein may be any suitable metal or alloy, such as, but not limited to, copper and / or aluminum.

[0031] The graphite layer 124 shown in the embodiment of FIG. 5 is provided to facilitate the diffusion of heat both across the S-cell 121 and towards the cold plate 102 (FIG. 3). The crystalline structure of graphite provides it with high thermal conductivity, which is useful for conducting heat flux towards the cold plate 102. However, graphite does not have an isothermal profile. Rather, graphite has a non-isothermal profile with high thermal conductivity along two axes and low thermal conductivity along the third axis. To account for the non-isothermal profile of graphite, the S-cell 121 is designed in a rectangular shape such that its length dimension is greater than its width dimension. Referring to FIG. 5, the graphite layer 124 has high thermal conductivity along the X-axis and Z-axis shown in FIG. 5. Thus, the S-cell 121 is designed such that the dimension along the X-axis is greater than the dimension along the Y-axis. That is, the width w of the S cell 121 generally corresponds to the Y axis of the coordinate system, the length l of the S cell 121 generally corresponds to the X axis of the coordinate system, and the depth d of the S cell 121 generally corresponds to the Z axis of the S cell 121. The length l and width w generally define a plane that gives the S cell 121 a rectangular shape as described herein, and more generally defines a lateral plane in which the recess 127 is oriented. The depth d generally defines a thickness of the S cell 121, and more generally defines a vertical plane in which the recess 127 is oriented.

[0032] Due to the rectangular shape of the S-cell and the properties of graphite, the length l and depth d of the S-cell 121 define a direction of relatively high thermal conductivity, while the width w of the S-cell 121 defines a direction of relatively low thermal conductivity. In a non-limiting example, the thermal conductivity of the S-cell 121 in the direction along the X-axis and Z-axis may be about 1500 W / (mK), while the thermal conductivity of the S-cell 121 in the direction along the y-axis may be about 10 W / (mK). In another non-limiting example, the ratio of the thermal conductivity of the S-cell 121 in the direction along the X-axis and Z-axis to the Y-axis may be about 100:1, about 150:1, or greater than about 150:1. As a result, heat flux is more likely to move in the direction along the X-axis and Z-axis relative to the Y-axis, and therefore more likely to move in the direction along the X-axis and Z-axis along the length l and depth d of the S-cell 121. This transfer of heat flux reduces the transfer of heat flux to adjacent S-cells 121 along the Y-axis, avoiding the problem of adjacent S-cells 121 overheating each other. As described in more detail herein, thermal vias can be provided at the edges of the S-cells along the X-axis to receive the heat flux and transfer it towards the cold plate 102. The heat flux also travels along the Z-axis towards the cold plate 102.

[0033] The second metal layer 126 of the S-cell 121 has a recess 127 formed in its second surface 128. The recess 127 can be formed, for example, by chemical etching. The recess 127 has a size and shape to receive the power electronic device 140 (see, for example, FIGS. 3 and 6). The second surface 128 can generally be a second major surface or surface of the second metal layer 126 that is opposite the first surface 125 (configured as the first major surface or surface of the second metal layer 126). That is, the second metal layer 126 can be a planar layer with the first surface 125 facing the graphite layer 124 and the opposite second surface 128 facing the power electronic device 140 and the circuit board assembly 106 (FIG. 3).

[0034] FIG. 6 shows a partial exploded view of a power electronic device assembly 146 including a power electronic device 140 including an S-cell 121 and a cold plate 102. FIG. 6 shows the power electronic device 140 and a bonding layer 143 relative to the recess 127 of the S-cell 121. The bonding layer 143 may be, for example, a solder layer. As another example, the bonding layer 143 may be a transient liquid phase bond layer 143. The power electronic device 140 includes a plurality of electrodes 141, 142 on its top surface. The larger electrode 141 may be a power electrode, and the smaller electrode 142 may be a signal electrode. It is noted that, although not visible in FIG. 6, the power electronic device 140 further includes one or more electrodes on its bottom surface. The one or more electrodes on the bottom surface of the power electronic device are electrically connected to the second metal layer 126 by placing the power electronic device 140 in the recess 127. In this manner, electrical connection to the bottom electrodes of the power electronic device 140 can be made via the second metal layer 126.

[0035] Referring also to FIG. 3, electrical connections to the electrodes 141, 142 and the second metal layer 126 may be made by a number of vias 112. These vias 112 may provide a drive signal to the power electronic device 140 as well as provide a current path for switching current. It should be noted that in some embodiments, some of the vias 112 may be configured as thermal vias that do not carry a drive signal or switching current. Additionally, the placement of the S-cells within the cavity 103 of the cold plate 102 allows for flux transfer from the power electronic device 140 through the S-cells to the cold plate as described herein. In this way, heat flux is optimally directed away from the power electronic device 140 and towards the cold plate 102 through the S-cells 121. As shown in FIG. 3, cold coolant 135 enters the cold plate 102 through the fluid inlet 132, flows through the fluid chamber 115, and exits through the fluid outlet 134 as warmed coolant.

[0036] Still referring to FIG. 3 and FIG. 6, the cavity 103 of the cold plate 102 may be shaped and / or sized to receive the S-cell 121 in which the power electronic device 140 is embedded or coupled, as described herein. A bonding material 180 may be disposed between the S-cell 121 and one or more walls of the cavity 103 of the cold plate 102. For example, the S-cell 121 may be bonded within the cavity 103 by applying the bonding material 180 to the base wall 104 and / or one or more side walls of the cavity 103 to secure the S-cell 121 within the cavity 103. The bonding material 180 is generally not limited by the present disclosure and may generally be any material that provides bonding properties. In some embodiments, the bonding material 180 may be a material that acts as an electrical insulator, such as a dielectric. In another example, the bonding material 180 may be an IMS dielectric material. However, other materials having electrical insulating properties are contemplated and are within the scope of the present disclosure.

[0037] It should be appreciated that embodiments of the present disclosure are directed to a power electronics system having a circuit board assembly coupled to a power electronics device assembly including a cold plate including S-cells. The power electronics device may be embedded within the S-cells and / or within the circuit board assembly. The S-cells are formed from graphite or graphite composites and are specifically dimensioned such that the thermal conductivity of the S-cells causes heat flux to move toward the cold plate and away from adjacent S-cells. Such a power electronics system is compact and maintains the ability to electrically isolate the S-cells while improving thermal conductivity, thereby improving heat flux from the S-cells to the cold plate and improving thermal spreading and cooling performance of the PCB compared to conventional packages.

[0038] It should be noted that the terms "substantially" and "about" may be utilized herein to express the degree of inherent uncertainty that may result from any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to express the degree to which a quantitative representation may vary from the stated basis without resulting in a change in the basic functionality of the subject matter at issue.

[0039] While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications can be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.

[0040] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus, this specification is intended to cover modifications and variations of the various embodiments described herein, provided that such modifications and variations come within the scope of the appended claims and their equivalents. The invention disclosed in this specification includes the following aspects. <Aspect 1> A cold plate comprising: an S-cell having a body comprising graphite or a graphite composite, the body defining a recess for a power device, the S-cell being disposed within a cavity in the cold plate; a bonding material for bonding the S cell to a base wall of the cavity; A cold plate comprising: <Aspect 2> The body of the S-cell has a length, a width, and a depth, and the length and depth of the S-cell have a high thermal conductivity relative to the width of the S-cell. 2. The cold plate of embodiment 1. <Aspect 3> The body of the S cell has a length and a width, the length being greater than the width; 2. The cold plate of embodiment 1. <Aspect 4> The graphite composite material of the body of the S cell comprises graphite and a metal portion at least partially surrounding the graphite. 2. The cold plate of embodiment 1. <Aspect 5> The metal portion completely surrounds the graphite. 5. The cold plate of embodiment 4. <Aspect 6> The metal portion is formed of copper or a copper-containing material. 5. The cold plate of embodiment 4. <Aspect 7> the bonding material comprises a thermally insulating material; 2. The cold plate of embodiment 1. <Aspect 8> The thermal insulating material is a dielectric material. 8. The cold plate of embodiment 7. <Aspect 9> The dielectric material is an insulated metal substrate material. 9. The cold plate of embodiment 8. <Aspect 10> the cold plate further comprises a fluid chamber, a fluid inlet, and a fluid outlet; the fluid inlet and the fluid outlet are thermally coupled to the fluid chamber; 2. The cold plate of embodiment 1. <Aspect 11> 1. A power electronic device assembly, comprising: A cold plate defining a cavity, an S-cell disposed within the cavity of the cold plate, the S-cell having a body including graphite or a graphite composite material, the body defining a recess for a power device; a bonding material for bonding the S cell to a base wall of the cavity; A cold plate comprising: a power electronic device embedded in a recess of the power device of the S cell; A power electronics device assembly comprising: <Aspect 12> The power electronic device is sintered onto one or more surfaces of the recess in the power device. 12. A power electronic device according to embodiment 11. <Aspect 13> The body of the S-cell has a length, a width, and a depth, and the length and depth of the S-cell have a high thermal conductivity relative to the width of the S-cell. 12. A power electronics device assembly as described in embodiment 11. <Aspect 14> The body of the S cell has a length and a width, the length being greater than the width; 12. A power electronics device assembly as described in embodiment 11. <Aspect 15> the body of the S cell further comprises a metal portion partially surrounding the graphite or graphite composite material; 12. A power electronics device assembly as described in embodiment 11. <Aspect 16> the bonding material comprises an insulated metal substrate material; 12. A power electronics device assembly as described in embodiment 11. <Aspect 17> 1. A power electronics system comprising: a circuit board assembly; a power electronics device assembly coupled to the circuit board assembly, A cold plate defining a cavity, an S-cell disposed within the cavity of the cold plate, the S-cell having a body including graphite or a graphite composite material, the body defining a recess for a power device; a bonding material for bonding the S cell to a base wall of the cavity; A cold plate comprising: a power electronic device embedded in a recess of the power device of the S cell; a power electronics device assembly comprising: A power electronics system comprising: <Aspect 18> the cold plate is coupled to a first surface of the cold plate and to the circuit board assembly; a capacitor is coupled to a second surface of the cold plate opposite the first surface; 18. The power electronics system of claim 17. <Aspect 19> The body of the S-cell has a length, a width, and a depth, and the length and depth of the S-cell have a high thermal conductivity relative to the width of the S-cell. 18. The power electronics system of claim 17. <Aspect 20> The body of the S cell has a length and a width, the length being greater than the width; 18. The power electronics system of claim 17.

Claims

1. A cold plate comprising: an S-cell having a body comprising graphite or a graphite composite material, the body defining a recess for a power device, the S-cell being disposed within a cavity in the cold plate; a bonding material for bonding the S cell to a base wall of the cavity; A cold plate comprising:

2. the body of the S cell has a length, a width, and a depth, the length and depth of the S cell having a high thermal conductivity relative to the width of the S cell; The cold plate of claim 1 .

3. The body of the S cell has a length and a width, the length being greater than the width. The cold plate of claim 1 .

4. The graphite composite material of the body of the S cell comprises graphite and a metal portion at least partially surrounding the graphite. The cold plate of claim 1 .

5. The metal portion completely surrounds the graphite. The cold plate of claim 4.

6. The metal portion is formed of copper or a copper-containing material. The cold plate of claim 4.

7. The bonding material comprises an electrically insulating material. The cold plate of claim 1 .

8. The electrically insulating material is a dielectric material. The cold plate of claim 7.

9. The dielectric material is an insulated metal substrate material. The cold plate of claim 8.

10. the cold plate further comprises a fluid chamber, a fluid inlet, and a fluid outlet; the fluid inlet and the fluid outlet are thermally coupled to the fluid chamber; The cold plate of claim 1 .

11. A power electronics device assembly comprising: A cold plate defining a cavity, an S cell disposed within the cavity of the cold plate, the S cell having a body including graphite or a graphite composite material, the body defining a recess for a power device; a bonding material for bonding the S cell to a base wall of the cavity; A cold plate comprising: a power electronic device embedded in a recess of the power device of the S cell; A power electronics device assembly comprising:

12. The power electronics device is sintered onto one or more surfaces of the recess in the power device.

12. A power electronic device according to claim 11.

13. The body of the S cell has a length, a width, and a depth, and the length and depth of the S cell have a high thermal conductivity relative to the width of the S cell.

12. The power electronic device assembly of claim 11.

14. The body of the S cell has a length and a width, the length being greater than the width.

12. The power electronic device assembly of claim 11.

15. The body of the S cell further comprises a metal portion partially surrounding the graphite or graphite composite material.

12. The power electronic device assembly of claim 11.

16. The bonding material comprising an insulated metal substrate material.

12. The power electronic device assembly of claim 11.

17. A power electronics system comprising: a circuit board assembly; a power electronics device assembly coupled to the circuit board assembly, A cold plate defining a cavity, an S cell disposed within the cavity of the cold plate, the S cell having a body including graphite or a graphite composite material, the body defining a recess for a power device; a bonding material for bonding the S cell to a base wall of the cavity; A cold plate comprising: a power electronic device embedded in a recess of the power device of the S cell; a power electronics device assembly comprising: A power electronics system comprising:

18. The cold plate, a first surface of which is coupled to the circuit board assembly; a capacitor is coupled to a second surface of the cold plate opposite the first surface; 20. The power electronics system of claim 17.

19. The body of the S cell has a length, a width, and a depth, and the length and depth of the S cell have a high thermal conductivity relative to the width of the S cell.

20. The power electronics system of claim 17.

20. The body of the S cell has a length and a width, the length being greater than the width.

20. The power electronics system of claim 17.

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