Elongated heat sink for use in converter assemblies

• US 6,721,181 B1
• Filed: 09/27/2002
• Issued: 04/13/2004
• Est. Priority Date: 09/27/2002
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kasunich, John M., Pfeifer, David W.
• Primary Examiner(s): TOLIN, GERALD P
• Application Number:
  US10/260,783
• Publication Number:
  US 20040060692A1
• Time in Patent Office: 564 Days
• Field of Search: 298/900.3, 363/141, 363/144, 174/16.3, 174/15.1, 257/706, 257/707, 257/713, 257/714, 257/723, 257/724, 622/592, 165/80.3, 165/80.4, 165/185, 165/104.33, 361/704, 361/705, 361/707-712, 361/717-719, 361/722, 361/690, 361/699, 361/689
• US Class Current: 361/704
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections

Abstract

An apparatus for sinking heat away from a plurality of power switching devices where each power switching device includes a heat dissipating surface having a dissipating width dimension and having a device length dimension perpendicular to the dissipating width dimension, the apparatus comprising a heat sink member having a sink length dimension between inlet and outlet ends, forming an internal channel that extends substantially along the entire sink length dimension and also forming inlet and outlet ports that open into the channel at the inlet and outlet ends, respectively, the sink including first and second oppositely facing surfaces, the second surface for receiving the heat dissipating surfaces of the power switching devices, the second surface having a receiving width dimension that is substantially perpendicular to the sink length dimension and that is less than twice the device dissipating width dimension.

Claims

1. A power sink assembly comprising:

a plurality of power switching devices where each power switching device includes a heat dissipating surface having a dissipating width dimension and having a device length dimension perpendicular to the dissipating width dimension; and

a heat sink member having a sink length dimension between inlet and outlet ends, forming an internal channel that extends substantially along the entire sink length dimension and also forming inlet and outlet ports that open into the channel at the inlet and outlet ends, respectively, the channel having a receiving width dimension substantially perpendicular to the sink length dimension that is less than twice the dissipating width dimension, the sink including first and second oppositely facing surfaces, a portion of the second surface adjacent the channel substantially receiving the heat dissipating surfaces of the power switching devices.

2. The apparatus of claim 1 wherein the receiving width dimension is substantially similar to the dissipating width dimension.

3. The apparatus of claim 2 wherein each switching device includes a device mounting surface, the mounting surface including the device dissipating surface and forming a device width dimension that is larger than the dissipating width dimension, the dissipating surface including the portion of the mounting surface from which heat is dissipated.

4. The apparatus of claim 3 wherein the sink member forms a sink width dimension that is substantially parallel to and greater than the receiving width dimension and wherein the sink width dimension and the device width dimension are substantially similar.

5. The apparatus of claim 4 wherein the sink length dimension is substantially similar to the combined lengths of the power switching devices.

6. The apparatus of claim 5 wherein, when the power switching devices are aligned end to end to form a device row with first and last devices at either end of the device row, oppositely facing edges of the dissipating surfaces of the first and last devices define a dissipating length and wherein a channel length is substantially similar to the dissipating length.

7. The apparatus of claim 6 further including at least one divider member formed in the channel and that extends substantially from the inlet end to the outlet end thereby dividing the channel into at least first and second substantially parallel channels.

8. The apparatus of claim 7 further including second and third divider members juxtaposed on opposite sides of the one divider member and that further divide the first and second channels into inner and outer first channels and inner and outer second channels, respectively, and, wherein, each of the second and third dividers form openings between the respective inner and outer channels.

9. The apparatus of claim 8 wherein the openings are substantially equi-spaced along the lengths of the second and third divider members.

10. The apparatus of claim 7 wherein the divider member is substantially perpendicular to the second surface.

11. The apparatus of claim 10 wherein the divider member extends to the inlet end of the channel and the sink member also forms a manifold chamber between the inlet and the channel, the manifold chamber opening into the first and second channels through first and second nozzles, respectively.

12. The apparatus of claim 11 wherein the divider member is terminated prior to the outlet end so that the first and second channels come together at the outlet end.

13. The apparatus of claim 4 wherein each device includes first and second mounting flanges that form portions of the mounting surface and that are separated by the dissipating surface, each mounting flange having a flange width dimension and, wherein, the sink includes a lateral wall member on either side of the channel having a wall thicknesses that is substantially similar to the flange width dimensions.

14. The apparatus of claim 13 wherein each mounting flange forms at least one flange mounting aperture and wherein the lateral walls form wall mounting apertures that align with the flange apertures and wherein the apparatus further includes a separate securing member for each of the flange/wall apertures pairs.

15. The apparatus of claim 1 wherein the inlet and outlet ports open through the first surface of the sink.

16. The apparatus of claim 1 wherein the sink member includes a body member and a cover member, the body member forming the second sink surface, including a first body member surface facing in a direction opposite the second surface and forming a cavity in the first surface, the cover member including at least a first cover surface, one of the cover member and the body member forming the inlet and one of the cover member and the body member forming the outlet, the cover member first surface hermetically sealed to the body member first surface to enclose the cavity and form the sink channel.

17. A power brick apparatus comprising:

a plurality of power switching devices, each device including a heat dissipating surface having a dissipating width dimension and having a device length dimension perpendicular to the dissipating width dimension; and

a heat sink member having a sink length dimension between inlet and outlet ends, forming an internal channel that extends substantially along the entire sink length dimension and also forming inlet and outlet ports that open into the channel at the inlet and outlet ends, respectively, the channel having a receiving width dimension substantially perpendicular to the sink length dimension that is less than twice the dissipating width dimension, the sink including first and second oppositely facing surfaces, a portion of the second surface adjacent the channel substantial receiving the heat dissipating surfaces of the power switching devices;

wherein, the power switching devices are mounted end to end so that their combined length extends along the sink length.

18. The apparatus of claim 17 wherein the receiving width dimension is substantially similar to the dissipating width dimension and is defined by the channel.

19. The apparatus of claim 18 wherein each switching device includes a device mounting surface, the mounting surface including the device dissipating surface and forming a device width dimension that is larger than the dissipating width dimension, the dissipating surface including the portion of the mounting surface from which heat is dissipated.

20. The apparatus of claim 19 wherein the sink member forms a sink width dimension that is substantially parallel to and greater than the receiving width dimension and wherein the sink width dimension and the device width dimension are substantially similar.

21. The apparatus of claim 20 wherein the sink length dimension is substantially similar to the combined lengths of the power switching devices.

22. The apparatus of claim 21 further including at least first, second and third divider members formed in the channel and that extends substantially from the inlet end to the outlet end thereby dividing the channel into at least four separate and substantially parallel channels, the first divider member juxtaposed between the second and third divider members, each of the second and third divider members forming a plurality of openings along the divider members length, the divider members substantially perpendicular to the second surface.

23. The apparatus of claim 22 wherein the divider member extends to the inlet end of the channel and the sink member also forms a manifold chamber between the inlet and the channel, the manifold chamber opening into the first and second channels through first and second nozzles, respectively and, wherein, the divider member is terminated prior to the outlet end so that the first and second channels come together at the outlet end.

24. The apparatus of claim 17 wherein each device includes first and second lateral extensions that are separated by the dissipating surface width dimension and wherein the channel separates lateral sink walls and wherein the lateral extensions cooperate with the lateral walls to secure the devices to the sink member.

25. The apparatus of claim 18 wherein each of the devices includes connector leads that extend to one side of the device and wherein the devices are mounted to the sink member with all of the leads extending to one side of the sink member and in a direction substantially perpendicular to the sink length dimension.

26. A method for sinking heat away from a plurality of power switching devices where each power switching device includes a heat dissipating surface having a dissipating width dimension and having a device length dimension perpendicular to the dissipating width dimension, the method comprising the steps of:

providing a body member having a sink length dimension between inlet and outlet ends, having first and second oppositely facing surfaces, the second surface having a receiving width dimension that is substantially perpendicular to the sink length dimension and that is substantially similar to the device dissipating width dimension;

forming a cavity in the first surface of the body member that extends substantially along the entire sink length dimension and that has a receiving width dimension that is substantially perpendicular to the sink length;

providing a cover member;

forming an inlet in one of the body member and the cover member;

forming an outlet in one of the body member and the cover member;

hermetically sealing the cover member to the first surface of the body member so that the cover member and cavity together form a channel and so that the inlet and outlet open into opposite ends of the channel; and

mounting the devices to the second surface with the dissipating width dimensions substantially parallel to the receiving width dimension.

27. The method of claim 26 wherein each of the devices includes connector leads that extend to one side of the device and wherein the step of mounting includes mounting all of the devices to the sink member with all of the leads extending to one side of the sink member and in a direction substantially perpendicular to the sink length dimension.

28. The method of claim 26 wherein the step of forming the channel includes forming four substantially parallel channels that are separated by divider members that are substantially perpendicular to the second surface the divider members including a first divider member that is disposed between a second and a third divider member and providing openings between adjacent channels and through the second and third divider members.

29. The method of claim 28 step of providing the channels further includes providing the first divider member so as to extend to the inlet end of the channel and wherein the method further includes the step of forming a manifold chamber between the inlet and the channel, the manifold chamber opening into the first and second channels through first and second nozzles, respectively.

30. An apparatus for sinking heat away from a plurality of power switching devices where each power switching device includes a heat dissipating surface having a dissipating width dimension and having a device length dimension perpendicular to the dissipating width dimension, the apparatus comprising:

a heat sink member having a sink length dimension between inlet and outlet ends, forming an internal channel that extends substantially along the entire sink length dimension and also forming inlet and outlet ports that open into the channel at the inlet and outlet ends, respectively, the channel having a receiving width dimension substantially perpendicular to the sink length dimension that is less than twice the dissipating width dimension, the sink including first and second oppositely facing surfaces, a portion of the second surface adjacent the channel substantially receiving the heat dissipating surfaces of the power switching devices.

31. The apparatus of claim 30 wherein the receiving width dimension is substantially similar to the dissipating width dimension.

32. The apparatus of claim 31 wherein the receiving width dimension is defined by the channel.

33. The apparatus of claim 30 further including at least one divider member formed in the channel and that extends substantially from the inlet end to the outlet end thereby dividing the channel into at least first and second substantially parallel channels.

34. The apparatus of claim 33 further including second and third divider members juxtaposed on opposite sides of the one divider member and that further divide the first and second channels into inner and outer fist channels and inner and outer second channels, respectively, and, wherein, each of the second and third dividers form openings between the respective inner and outer channels.

35. The apparatus of claim 34 wherein the openings are substantially equi-spaced along the lengths of the second and third divider members.

36. The apparatus of claim 33 wherein the divider member is substantially perpendicular to the second surface.

37. The apparatus of claim 36 wherein the divider member extends to the inlet end of the channel and the sink member also forms a manifold chamber between the inlet and the channel, the manifold chamber opening into the first and second channels through first and second nozzles, respectively.

38. The apparatus of claim 37 wherein the divider member is terminated prior to the outlet end so that the first and second channels come together at the outlet end.

39. The apparatus of claim 30 wherein the inlet and outlet ports open through the first surface of the sink.

40. The apparatus of claim 30 wherein the sink member includes a body member and a cover member, the body member forming the second sink surface, including a first body member surface facing in a direction opposite the second surface and forming a cavity in the first surface, the cover member including at least a first cover surface, one of the cover member and the body member forming the inlet and one of the cover member and the body member forming the outlet, the cover member first surface hermetically sealed to the body member first surface to enclose the cavity and form the sink channel.