Cooled electrical terminal assembly and device incorporating same

• US 6,898,072 B2
• Filed: 12/23/2002
• Issued: 05/24/2005
• Est. Priority Date: 01/16/2002
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Kehl, Dennis L., Kannenberg, Daniel G., Kaishian, Steven C., Radosevich, Lawrence D., Beihoff, Bruce C., Phillips, Mark G.
• Primary Examiner(s): DATSKOVSKIY, MICHAIL V
• Application Number:
  US10/252,183
• Publication Number:
  US 20030133267A1
• Time in Patent Office: 883 Days
• Field of Search: 361/704, 361/707, 361708-712, 361/784, 361/785, 361/676, 361/688, 361/699, 361/701, 257/696, 257/706, 257/713, 257/723, 257/724, 257/796, 174/16.3, 165/104.33, 165/80.3, 165/80.4, 363/131, 363/132, 363/95, 363/98, 363/16, 363/17, 363/39, 363/141, 363/142, 363/134, 363/136, 318/138, 318/254, 318/439, 318/538, 318/722, 318/801
• US Class Current: 361/676
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/50 using propulsion power supplied by batteries or fuel cells
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• 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
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A terminal structure provides interfacing with power electronics circuitry and external circuitry. The thermal support may receive one or more power electronic circuits. The support may aid in removing heat from the terminal structure and the circuits through fluid circulating through the support. The support may form a shield from both external EMI/RFI and from interference generated by operation of the power electronic circuits. Features may be provided to permit and enhance connection of the circuitry to external circuitry, such as improved terminal configurations. Modular units may be assembled that may be coupled to electronic circuitry via plug-in arrangements or through interface with a backplane or similar mounting and interconnecting structures.

Claims

1. An electrical component assembly comprising:

a thermal support for receiving electrical components that generate heat during operation; and

an electrical terminal assembly mounted to the support and configured to be electrically coupled to electrical components received on the support, the terminal assembly including an electrically insulating and thermally conducting body, a plurality of conductive elements supported in and insulated from one another by the body, and at least one cooling element contacting the body to extract heat therefrom during operation.

2. The electrical component assembly of claim 1, wherein the body is made of a ceramic-filled thermoplastic.

3. The electrical component assembly of claim 1, wherein the body is made of a liquid crystal polymer.

4. The electrical component assembly of claim 1, wherein the cooling element includes a conduit for routing a cooling fluid through at least a portion of the body.

5. The electrical component assembly of claim 1, wherein the cooling element includes a thermal extension for conducting heat from the body.

6. The electrical component assembly of claim 1, wherein the terminal assembly includes a two incoming power conductors and three outgoing power conductors.

7. The electrical component assembly of claim 6, wherein the incoming power conductors are disposed between respective outgoing power conductors.

8. The electrical component assembly of claim 1, wherein the terminal assembly includes integral connection pads for interconnecting the terminal assembly with the power converter circuit.

9. The electrical component assembly of claim 1, wherein the terminal assembly comprises a integral structure removably secured to the thermal support.

10. The electrical component assembly of claim 1, wherein the terminal assembly is directly mounted adjacent to an edge of the support.

11. A modular power converter comprising:

a thermal support;

a power converter circuit secured to the thermal support and cooled by the thermal support during operation; and

a terminal element supported on the thermal support and including an electrically insulating but thermally conducting body carrying conductors for transfer of power between the power converter circuit and external circuitry, the terminal element being configured to transfer heat from the conductors via heat transfer to the thermal support during operation.

12. The modular power converter of claim 11, wherein the body is made of a ceramic-filled thermoplastic.

13. The modular power converter of claim 11, wherein the body is made of a liquid crystal polymer.

14. The modular power converter of claim 11, wherein the cooling element includes a conduit for routing a cooling fluid through at least a portion of the body.

15. The modular power converter of claim 11, wherein the cooling element includes a thermal extension for conducting heat from the body.

16. The modular power converter of claim 11, wherein the terminal element comprises a integral structure removably secured to the thermal support.

17. The modular power converter of claim 11, wherein the terminal element includes an insulative body in which the conductors are secured.

18. The modular power converter of claim 11, wherein the terminal assembly includes a two incoming power conductors and three outgoing power conductors.

19. The modular power converter of claim 18, wherein the incoming power conductors are disposed between respective outgoing power conductors.

20. The modular power converter of claim 11, wherein the terminal element is configured to interface with the power converter circuit and with an energy storage or conditioning circuit.

21. The modular power converter of claim 11, wherein the terminal element comprises an electrically insulative and thermally conductive polymer.

22. The modular power converter of claim 11, wherein the terminal element includes integral connection pads for interconnecting the terminal element with the power converter circuit.

23. The modular power converter of claim 11, wherein the terminal element is directly mounted adjacent to an edge of the support.

24. A modular power converter comprising:

a thermal support;

a power converter circuit secured to the thermal support and cooled by the thermal support during operation; and

a terminal assembly including a plurality of terminals and a net like insulator structure supporting the terminals and defining at least one thermal conduction path for directing thermal energy from the terminals.

25. The modular power converter of claim 24, wherein the terminal assembly comprises a integral structure removably secured to the thermal support.

26. The modular power converter of claim 24 wherein the terminal assembly includes a two incoming power conductors and three outgoing power conductors.

27. The modular power converter of claim 26, wherein the incoming power conductors are disposed between respective outgoing power conductors.

28. The modular power converter of claim 24, wherein the terminal assembly is configured to interface with the power converter circuit and with an energy storage or conditioning circuit.

29. The modular power converter of claim 24, wherein the insulator structure of the terminal assembly comprises an electrically insulative and thermally conductive polymer.

30. The modular power converter of claim 24, wherein the terminal assembly includes integral connection pads for interconnecting the terminal assembly with the power converter circuit.

31. The modular power converter of claim 24, wherein the terminal assembly is directly mounted adjacent to an edge of the support.

32. A modular power converter comprising:

a controlled power electronics circuit including solid state switches configured to convert incoming power to controlled outgoing power; and

a fluid cooled support on which at least the power electronics circuit is directly secured, the fluid cooled support including inlet and outlet ports for a cooling fluid and an internal fluid conduit for directing flow of cooling fluid adjacent to the power electronics circuit for removal of heat therefrom; and

a terminal assembly coupled to the support for conducting incoming power to the power electronics circuit and for conducting outgoing power from the power electronics circuit, the terminal assembly being convectively cooled at least indirectly by the cooling fluid flow through the support during operation, wherein the incoming power conductors are disposed between respective outgoing power conductors.

33. The modular power converter of claim 32, wherein the terminal assembly includes an insulative body in which a plurality of terminal conductors are secured.

34. The modular power converter of claim 32, wherein the terminal assembly includes a two incoming power conductors and three outgoing power conductors.

35. The modular power converter of claim 32, wherein the terminal assembly is configured to interface with the power electronics circuit and with an energy storage or conditioning circuit.

36. The modular power converter of claim 32, wherein the terminal assembly comprises an electrically insulative and thermally conductive polymer.

37. The modular power converter of claim 32, wherein the terminal assembly includes integral connection pads for interconnecting the terminal assembly with the power electronics circuit.

38. The modular power converter of claim 32, wherein the terminal assembly is directly mounted adjacent to an edge of the support.

39. A method for converting electrical power comprising the steps of:

converting input power to controlled output power via a converter including a power converter circuit, a thermal support for the converter circuit, and a terminal assembly supported on the thermal support for transmitting power between the power converter circuit and external circuitry; and

extracting heat from the terminal assembly via the thermal support during operation, wherein the terminal assembly includes a two incoming power conductors and three outgoing power conductors disposed in a thermally conducting and electrically insulating body, and wherein heat is extracted from the power conductor via the body.

40. The method of claim 39, wherein the support includes inlet and outlet ports for a cooling fluid and a coolant circulation path therebetween, and wherein heat is extracted from the terminal assembly via circulation of cooling fluid through the circulation path.

41. The method of claim 40, wherein the circulation path is defined generally adjacent to the terminal assembly.

42. The method of claim 39, wherein the terminal assembly includes a thermally conductive path and the method includes extracting heat from the terminal assembly via the conductive path.

43. The method of claim 39, wherein the incoming power conductors are disposed between respective outgoing power conductors and heat is extracted in a direction generally perpendicular to a plane of alignment of the conductors.

44. The method of claim 39, wherein the terminal assembly is configured to interface with the power converter circuit and with an energy storage or conditioning circuit, and wherein heat extracted via the support includes heat extracted from the power converter circuit, the energy storage or conditioning circuit and the terminal assembly.

45. The method of claim 39, wherein the terminal assembly comprises an electrically insulative and thermally conductive polymer body and wherein heat extracted from the terminal assembly flows through the polymer body.

46. A modular power converter comprising:

means for converting input power to controlled output power via a converter including a power converter circuit, a thermal support for the converter circuit, and a terminal assembly supported on the thermal support and including an electrically insulating but thermally conducting body for transmitting power between the power converter circuit and external circuitry; and

means for extracting heat from the terminal assembly via the thermal support during operation.