Laminated bus bar for use with a power conversion configuration

• US 6,822,850 B2
• Filed: 06/05/2003
• Issued: 11/23/2004
• 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: Pfeifer, David W., Sheppard, Richard, Kasunich, John M.
• Primary Examiner(s): CHERVINSKY, BORIS LEO
• Application Number:
  US10/455,673
• Publication Number:
  US 20040062006A1
• Time in Patent Office: 537 Days
• Field of Search: 361/611, 361/637, 361/648, 361/624, 361/699, 361/704, 363/144, 363/147
• US Class Current: 361/611
• CPC Class Codes: F28D 2021/0029 Heat sinks
• CPC Class Codes: F28F 2265/10 for preventing overheating, e.g. heat shields thermal insulation F28F2270/00
• CPC Class Codes: F28F 3/12 Elements constructed in the shape of a hollow panel, e.g. with channels F28D1/02, F28D1/03 take precedence
• CPC Class Codes: H01L 23/473 by flowing liquids H01L23/4332, H01L23/4338 take precedence
• CPC Class Codes: H01L 25/16 the devices being of types provided for in two or more different main groups of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. forming hybrid circuits
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change

Abstract

An apparatus for linking together power switching devices having intra-converter connection terminals to form a power conversion assembly, the apparatus comprising a planar bus bar including positive and negative DC bus layers and insulating layers that insulate each of the DC bus layers, the bar also including at least a first external insulating layer that forms a first external surface of the bar, the bar also forming at least first and second linking edges and first and second pluralities of linkages formed along the first and second linking edges, respectively, each linkage linked to one of the positive and negative DC bus layers and configured to be linkable to at least one of the power switching device intra-converter connection terminals, in some cases positive and negative DC bus linkages are also provided to render the conversion assembly extremely versatile.

Claims

1. An apparatus for linking together power switching devices having intra-converter connection terminals to form a power conversion assembly, the apparatus comprising:

a planar bus bar including positive and negative DC bus layers and insulating layers that insulate each of the DC bus layers, the bar also including at least a first external insulating layer that forms a first external surface of the bar, the bar also forming at least first and second linking edges; and

first and second pluralities of linkages formed along the first and second linking edges, respectively, each linkage linked to one of the positive and negative DC bus layers and configured to be linkable to at least one of the power switching device intra-converter connection terminals.

2. The apparatus of claim 1 wherein each of the linkages is a linking tab.

3. The apparatus of claim 1 wherein first and second edges of the bus bar face in opposite directions.

4. The apparatus of claim 3 wherein the bus bar is substantially rectilinear.

5. The apparatus of claim 3 wherein the first and second edges are straight and wherein the first plurality of linkages are aligned along the first straight edge and the second plurality of linkages are aligned along the second straight edge.

6. The apparatus of claim 5 wherein the first and second linking edges are vertically aligned.

7. The apparatus of claim 1 further including first and second external linking vias open to the positive and negative DC bus layers, respectively.

8. The apparatus of claim 7 also for linking a plurality of capacitors to the switching devices wherein the external linking vias open through the fist external insulating layer and wherein the laminated bar further includes a second external insulating layer on a side opposite the first external insulating layer and forms a plurality of vias opening through second external insulating layer to the positive and negative DC bus layers, the capacitors linkable through the plurality of vias to the DC bus layers.

9. The apparatus of claim 7 further including positive and negative DC connection terminals that extend through the first and second vias and are linked to the positive and negative DC bus layers, distal ends of the DC connection terminals exposed and connectable to at least one of a DC source and a DC load.

10. The apparatus of claim 1 for linking at least first and second bridge assemblies together with the capacitors to form a conversion device and, wherein, each of the linkages in the first plurality is linked to at least one of the intra-converter connection terminals of the first bridge assembly and each of the linkages in the second plurality is linked to at least one of the intra-converter connection terminals of the second bridge assembly.

21. The apparatus of claim 9 wherein the sink member is a liquid cooled heat sink.

11. A three phase electronic converter assembly comprising:

at least a first heat sink member having a mounting surface;

first and second X phase converter bridge assemblies, each bridge assembly including a plurality of power switching devices, the first bridge assembly forming first through Xth external linkage terminals and the second bridge assembly forming (X+1)th through 2Xth external linkage terminals, each linkage terminal linkable to one phase of at least one of an X phase source and an X phase load, the switching devices mounted to the mounting surface of the at least first sink member;

a plurality of capacitors; and

a bus bar including a positive DC bus, a negative DC bus and a plurality of insulating layers that insulate the positive and negative DC buses and form an external insulating layer, the capacitors and each of the bridge assemblies linked to the positive and negative DC buses, the bar forming first and second external linking vias that open to the positive and negative DC buses, respectively.

12. The apparatus of claim 11 further including a positive DC bus connection terminal linked to the positive DC bus and having a distal end extending through the first via and exposed for external connection and a negative DC connection terminal linked to the negative DC bus and having a distal end extending through the second via and exposed for external connection.

13. The apparatus of claim 12 wherein the bus bar is planar proximate the first and second vias and wherein each of the positive and negative connection terminals extend substantially perpendicularly to the bus bar plane proximate the vias.

14. The apparatus of claim 13 including a second sink member having a mounting surface and, wherein, the first bridge assembly is mounted to the mounting surface of the first sink member and the second bridge assembly is mounted to the mounting surface of the second sink member.

15. The apparatus of claim 14 further including a bracket member rigidly linked to and between the first and second sink members, the plurality of capacitors mounted to the bracket member substantially between the first and second sink members.

16. The apparatus of claim 15 further including a controller for controlling each of the first and second bridge assemblies to operate as at least one of a rectifier and an inverter.

17. The apparatus of claim 15 wherein the first bridge assembly includes at least first and second three phase converter bridges and the second bridge assembly includes at least first and second three phase converter bridges.

18. The apparatus of claim 11 wherein X is 3.

19. The apparatus of claim 18 wherein the first three phase converter bridge assembly includes power switching devices that form at least first and second three phase bridges and the second three phase converter bridge assembly includes power switching devices that form at least first and second three phase bridges, each of the three phase bridges including three pairs of switching devices, each of the switching device pairs including an upper switching device and a lower switching device, each device including intra-converter connection terminals and inter-converter connection terminals, the linkage assembly linking the intra-converter connection terminals of each of the upper devices to the positive DC bus and linking the intra-converter connection terminals of each of the lower switching devices to the negative DC bus, the inter-converter connection terminals forming the first through third external linkage terminals of the first bridge assembly and forming the fourth through sixth external linkage terminals of the second bridge assembly.

20. The apparatus of claim 11 wherein the first bridge assembly includes at least first and second three phase converter bridges and the second bridge assembly includes at least first and second three phase converter bridges.

22. A three phase electronic converter assembly comprising:

a first heat sink member having a mounting surface;

a second heat sink member having a mounting surface;

first and second X phase converter bridge assemblies, each bridge assembly including a plurality of power switching devices, the first bridge assembly forming first through Xth external linkage terminals and the second bridge assembly forming (X+1)th through 2Xth external linkage terminals, each linkage terminal linkable to one phase of at least one of an X phase source and an X phase load, the first assembly switching devices mounted to the first sink member mounting surface and the second assembly switching devices mounted to the second sink member mounting surface;

a plurality of capacitors;

a bus bar including a positive DC bus, a negative DC bus and a plurality of insulating layers that insulate the positive and negative DC buses and form an external insulating layer, the capacitors and each of the bridge assemblies linked to the positive and negative DC buses, the external insulating layer forming first and second vias that open to the positive and negative DC buses, respectively.

23. The apparatus of claim 22 further including a positive DC bus connection terminal linked to the positive DC bus and having a distal end extending through the first via and exposed for external connection and a negative DC connection terminal linked to the negative DC bus and having a distal end extending through the second via and exposed for external connection.

24. The apparatus of claim 23 wherein the bus bar is planar proximate the first and second vias and wherein each of the positive and negative connection terminals extend substantially perpendicularly to the bus bar plane proximate the vias.