Compact liquid converter assembly

• US 6,956,742 B2
• Filed: 06/05/2003
• Issued: 10/18/2005
• Est. Priority Date: 09/27/2002
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Kasunich, John M., Pfeifer, David W., Sheppard, Richard
• Primary Examiner(s): Vortman, Anatoly
• Application Number:
  US10/455,593
• Publication Number:
  US 20040062005A1
• Time in Patent Office: 866 Days
• Field of Search: 361/689, 361/690, 361/698, 361/699, 361/700, 361/702, 361/703, 361/704, 361709-712, 361/715, 257/714, 257/715, 174/15.1, 174/15.2, 174/17.07, 174/17.08, 165 803- 805, 165/104.33
• US Class Current: 361/709
• CPC Class Codes: F28D 2021/0029 Heat sinks
• CPC Class Codes: F28F 2265/10 for preventing overheating, e.g. heat shields
• 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 electronic converter assembly comprising first and second liquid cooled heat sink members, each sink member having at least one sink mounting surface, first and second pluralities of power switching devices, each switching device including connection terminals, the first and second pluralities of switching devices mounted to the first and second sink mounting surfaces, respectively and a planar laminated bus bar including a plurality of conductors that link the power switching device connection terminals to form a power conversion topology.

Claims

1. An electronic converter assembly comprising:

first and second liquid cooled heat sink members, each sink member having at least one sink mounting surface;

first and second pluralities of power switching devices, each switching device including connection terminals, the first and second pluralities of switching devices mounted to the first and second sink mounting surfaces, respectively;

a planar laminated bus bar including a plurality of conductors that link the power switching device connection terminals to form a power conversion topology;

a plurality of capacitors; and

a bracket member having at least one bracket mounting surface and rigidly mounted to each of the first and second mink members, the capacitors mounted to the bracket mounting surface and the laminated bar further linking the switching device connection terminals and the capacitors to form the conversion topology.

2. The apparatus of claim 1 wherein the bracket member is mounted between the first and second sink members and first lateral surfaces of the first and second sink members face each other.

3. The apparatus of claim 2 wherein each capacitor includes a mounting end and a capacitor connection terminal at an end opposite the mounting end, is mounted to the bracket mounting surface at the mounting end and is dimensioned such that the connection terminal is substantially coplanar with the switching device connection terminals.

4. The apparatus of claim 3 wherein each of the sink members includes a second mounting surface that faces in a direction opposite the first mounting surface and wherein the bracket member is mounted to the second mounting surfaces.

5. The apparatus of claim 4 wherein the bracket member includes first and second lateral end members mounted to the second mounting surfaces of the first and second sink members, respectively, first and second intermediate members linked to and forming substantially 90 degree angles with the first and second proximate members and extending substantially parallel to the first lateral sides of the first and second sink members and generally away from the first and second sink members, respectively, and a central member linked between the first and second intermediate members, forming a substantially 90 degree angle with each of the intermediate members and extending generally between the first and second sink members, the capacitors mounted to the central member.

6. The apparatus of claim 5 wherein each of the devices includes a heat dissipating surface adjacent the mounting surface and is characterized by a device thickness dimension between the connection plane and the dissipating surface of the device, the first and second mounting surfaces on each of the sink members are separated by a sink thickness, each of the first and second intermediate members has an intermediate member length, each capacitor includes first and second oppositely facing ends and a length dimension between the first and second ends, the capacitor terminals extend axially from the first end of each capacitor and the second end of each capacitor is mounted to the central member and, wherein, the combined sink thickness, device thickness and intermediate member length is substantially similar to the capacitor length dimension.

7. The apparatus of claim 6 wherein each capacitor has a heat conducting extension that protrudes from the second end of the capacitor and that is in conductive contact with the distal end of the bracket member and wherein the bracket member is formed of a heat conducting material.

8. The apparatus of claim 1 wherein the first sink member has a first length dimension and forms a first internal channel along its length dimension between an inlet and an outlet and wherein the second sink member has a second length dimension and forms a second internal channel along its length dimension between an inlet and an outlet.

9. The apparatus of claim 8 wherein the sink members are oriented such that the first sink member inlet is below the first sink member outlet and the second sink member inlet is below the second sink member outlet.

10. The apparatus of claim 9 wherein the sink members are oriented such that the channels are substantially vertically oriented.

11. The apparatus of claim 1 wherein the laminated bus bar links the power switching devices together to form at least one of an inverter and a rectifier.

12. The apparatus of claim 11 wherein the laminated bus bar links the power switching devices together to form each of an inverter and a rectifier.

13. The apparatus of claim 12 wherein the first plurality of power switching devices forms the rectifier and the second plurality of power switching devices forms the inverter.

14. The apparatus of claim 1 wherein the switching devices are arranged six to a module and wherein each of the first and second pluralities includes at least two separate modules.

15. The apparatus of claim 14 wherein the bracket member is mounted between the first and second sink members.

16. The apparatus of claim 15 wherein the first and second pluralities are linked to form a rectifier and an inverter, respectively.

17. An electronic converter assembly comprising:

first and second liquid cooled heat sink members, each sink member having at least one sink mounting surface;

first and second pluralities of power switching devices, each switching device including connection terminals, the first and second pluralities of switching devices mounted to the first and second sink mounting surfaces, respectively; and

a planar laminated bus bar including a plurality of conductors that link the power switching device connection terminals to form a power conversion topology;

wherein each of the first and second sink members has first and second oppositely facing lateral surfaces, the mounting surfaces and first and second lateral surfaces form first and second lateral edges, respectively, on each of the sink members, the sink members juxtaposed such that the first lateral surfaces of the first and second sink members oppose each other.

18. The apparatus of claim 17 wherein the first plurality of power switching devices is mounted side by side on the first sink mounting surface forming a single row that extends substantially along the first sink length, each device in the first plurality including intra-converter terminals juxtaposed within a first connection plane and wherein the second plurality of power switching devices is mounted side by side on the second sink mounting surface forming a single row that extends substantially along the second sink length, each device in the second plurality including intra-converter terminals that are also juxtaposed within the first connection plane wherein the intra-converter connection terminals are the terminals linked to the laminated bus bar.

19. The apparatus of claim 18 wherein the intra-converter terminals of each device are located proximate the first lateral edge of the sink member to which the device is mounted.

20. The apparatus of claim 18 wherein each device also includes inter-converter connection terminals and wherein the inter-converter terminals of each device are located proximate the second lateral edge of the sink member to which the device is mounted and are within the first connection plane.

21. The apparatus of claim 20 further including first, second, third, fourth, fifth and sixth separate bus bars, each of the first, second and third bars linked to different sets of the inter-converter connection terminals on the first plurality of switching devices, the fourth, fifth and sixth bars linked to different sets of the inter-converter connection terminals on the second plurality of switching devices.

22. An electronic converter assembly comprising:

first and second liquid cooled heat sink members, each sink member having at least one sink mounting surface and a length dimension, each sink member forming an internal substantially vertical channel between an inlet and an outlet where the inlet is below the outlet;

a bracket member rigidly linked to the first and second sink members;

first and second pluralities of power switching devices mounted to the first and second sink mounting surfaces, respectively, each switching device including intra-converter connection terminals;

a linkage assembly including a plurality of conductors that link the power switching device intra-converter connection terminals to form a power conversion topology; and

a plurality of capacitors mounted to the bracket member between the first and second sink members and between the bracket member and the linkage assembly and wherein the capacitors are also linked to the linkage assembly.

23. A method for configuring a converter assembly, the method comprising the steps of:

providing first and second liquid cooled heat sink members where each member has a mounting surface and has a length dimension, each mounting surface having first and second lateral edges that extend along the length dimension and that face in opposite directions;

mounting a bracket member between the sink members such that the sink member length dimensions are substantially parallel and such that the first edges of the sink members face each other;

providing first and second pluralities of power switching devices where each device includes inter-converter connection terminals to be linked to a source or a load and intra-converter connection terminals to be linked to either a positive or a negative DC bus;

mounting the first and second pluralities of switching devices to the first and second sink member mounting surfaces with the intra-converter and the inter-converter connection terminals proximate the first and second edges of the mounting surfaces, respectively; and

linking the intra-converter connection terminals to positive and negative DC buses to form the converter topology.

24. The method of claim 23 further including the step of orienting the first and second sink members such that the length dimensions are substantially vertically oriented.

25. The method of claim 23 wherein the step of linking includes providing a laminated bus bar including positive and negative DC bus conducting layers and linking the intra-converter connection terminals to the positive and negative layers to configure the topology.

26. The method of claim 25 wherein the step of linking includes linking the first plurality of switching devices to form a rectifier and linking the second plurality of switches to form an inverter.