MOTOR CONTROLLER ASSEMBLY WITH CAPACITOR THERMAL ISOLATION

• US 20100290204A1
• Filed: 05/15/2009
• Published: 11/18/2010
• Est. Priority Date: 05/15/2009
• Status: Active Grant

• Current Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Pal, Debabrata
• Granted Patent: US 8,897,023 B2
• Time in Patent Office: Days
• US Class Current: 361/775
• CPC Class Codes: H05K 7/1432 specially adapted for power drive units or power converters
• CPC Class Codes: H05K 7/14322 wherein the control and power circuits of a power converter are arranged within the same casing
• CPC Class Codes: H05K 7/14329 specially adapted for the configuration of power bus bars

Abstract

An electrical assembly for a motor controller is disclosed that includes an electrical lead. The electrical lead has a conductive trace within an insulating material and that extends a length between first and second ends. An electrical pad is in electrical continuity with and extends from the conductive trace through the insulating material at the first end. The pad includes an aperture providing a securing feature. An electrical component is supported by and integral with the second end, in one example. The electrical component is in electrical continuity with the conductive trace at the second end. A bus bar provides a joint having a first cross-sectional area. The electrical lead is flexible and is removably secured to the joint by the securing feature to provide electrical continuity from a capacitor to the bus bar. The flexible electrical lead has a second cross-sectional area substantially less than the first cross-sectional area.

Claims

1. A motor controller comprising:

a capacitor;

a bus bar providing a joint having a first cross-sectional area;

a flexible electrical lead removably secured to the joint to provide electrical continuity from the capacitor to the bus bar, the flexible electrical lead having a second cross-sectional area substantially less than the first cross-sectional area.

2. The motor controller according to claim 1, wherein the flexible electrical lead includes a conductive trace covered in a polyimide insulating material.

3. The motor controller according to claim 2, wherein the bus bar and the conductive trace comprise copper.

4. The motor controller according to claim 2, wherein the flexible electrical lead includes a conductive pad extending from the conductive trace through the insulating material at the first end, the conductive pad including an aperture providing a securing feature.

5. The motor controller according to claim 4, wherein flexible electrical lead includes a generally rectangular cross-section, and comprising a fastening element extending through the aperture and removably securing the first end to the bus bar.

6. The motor controller according to claim 1, comprising a printed wiring board supporting the capacitor and a second end of the flexible electrical lead, which is opposite a first end of the flexible electrical lead that is secured to the bus bar, the printed wiring board including a conductive layer providing electrical continuity between the second end and the capacitor.

7. The motor controller according to claim 1, wherein the flexible electrical lead is connected directly to the capacitor at a second end of the flexible electrical lead.

8. The motor controller according to claim 7, comprising a housing surrounding the second end and the capacitor, the flexible electrical lead extending through the housing to a first end, the housing filled with a potting material.

9. The motor controller according to claim 1, comprising an inductor and a chassis, the bus bar and the capacitor supported by the chassis, and the bus bar electrically connected between the inductor and the capacitor.

10. An electrical assembly for a motor controller comprising:

an electrical lead including a conductive trace provided within an insulating material and extending a length between first and second ends, and an electrical pad in electrical continuity with and extending from the conductive trace through the insulating material at the first end, the pad including an aperture providing a securing feature; and

an electrical component supported by and integral with the second end, the electrical component in electrical continuity with the conductive trace at the second end.

11. The electrical assembly according to claim 10, wherein the electrical component is a printed wiring board supporting the second end, the printed wiring board including a conductive layer providing electrical continuity between the second end, the conductive trace provided by the conductive layer.

12. The electrical assembly according to claim 11, wherein the printed wiring board includes multiple conductive layers separated by insulating layers, the insulating layers and insulating material constructed from different materials, the conductive trace provided by one of the multiple conductive layers.

13. The electrical assembly according to claim 12, the insulating material comprising polyimide and the insulating layers comprising a prepreg resin material, the conductive trace and conductive layers comprising copper.

14. The electrical assembly according to claim 10, wherein the second end includes a conductive pad, and the electrical component is a capacitor having an electrical contact, the second end conductive pad supporting the contact.

15. The electrical assembly according to claim 14, wherein the electrical component includes a housing surrounding the second end and the capacitor, the housing filled with a potting material.

16. The electrical assembly according to claim 15, wherein a pair of the electrical leads extends from the housing, the capacitor interconnected to the pair of electrical leads and in continuity therewith.