Vehicle drive module having improved EMI shielding

• US 7,142,434 B2
• Filed: 12/26/2002
• Issued: 11/28/2006
• Est. Priority Date: 01/16/2002
• Status: Expired due to Fees

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kehl, Dennis L., Kaishian, Steven C., Radosevich, Lawrence D., Gettelfinger, Lee A., Beihoff, Bruce C., Phillips, Mark G.
• Primary Examiner(s): Cuneo, Kamand
• Assistant Examiner(s): Bui, Hung S.
• Application Number:
  US10/252,330
• Publication Number:
  US 20030133283A1
• Time in Patent Office: 1,433 Days
• Field of Search: 361/715, 361/790, 361/800, 361/818, 361/816, 361/752, 361/709, 361/797, 361/794, 165/122, 298/31, 363/146, 363/141, 174/35.R, 174/51
• US Class Current: 361/818
• 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

Abstract

EMI shielding in an electric vehicle drive is provided for power electronics circuits and the like via a direct-mount reference plane support and shielding structure. The thermal support may receive one or more power electronic circuits. The support may aid in removing heat from the circuits through fluid circulating through the support. The support forms 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 electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

an EMI shielding assembly including a cooled support incorporating integral EMI shielding features and at least partially defining an electrical reference plane, and an enclosure at least partially surrounding the cooled support and electrically coupled to the reference plane, the EMI shielding and the cooled support being electrically contiguous with one another; and

a power electronics circuit supported on the cooled support;

the shielding assembly providing contiguous shielding having intrinsically low impedance paths for EMI originating from the power electronics circuit and from sources external to the shield assembly during operation.

2. The electric vehicle drive of claim 1, further comprising low impedance conductive paths for EMI at connections to the EMI shielding assembly and power electronics circuit.

3. The electric vehicle drive of claim 1, wherein the integral EMI shielding features includes a flange at least partially surrounding the support.

4. The electric vehicle drive of claim 1, wherein the support is a single-piece support.

5. The electric vehicle drive of claim 1, wherein the enclosure comprises a metallic cover.

6. The electric vehicle drive of claim 1, wherein the enclosure includes a canister in which the support is disposed.

7. The electric vehicle drive of claim 1, wherein the enclosure includes a multi-piece housing in which the support is disposed.

8. The electric vehicle drive of claim 1, further comprising a connector system providing contiguous EMI shielding for conductors coupled between the power electronics circuit and external circuitry.

9. The electric vehicle drive of claim 1, wherein the support includes inlet and outlet ports and a coolant circulation path therebetween.

10. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a power electronics circuit;

an EMI shielding assembly including a support incorporating integral EMI shielding features that include a flange at least partially surrounding the support, and at least partially defining an electrical reference plane, and an enclosure at least partially surrounding the support and electrically coupled to the reference plane, the shielding assembly providing contiguous shielding having intrinsically low impedance paths for EMI originating from the power electronics circuit and from sources external to the shield assembly during operation; and

low impedance conductive paths for EMI at connections to the EMI shielding assembly and power electronics circuit.

11. The electric vehicle drive of claim 10, wherein the support is a single-piece support.

12. The electric vehicle drive of claim 10, wherein the enclosure comprises a metallic cover.

13. The electric vehicle drive of claim 10, wherein the enclosure includes a canister in which the support is disposed.

14. The electric vehicle drive of claim 10, wherein the enclosure includes a multi-piece housing in which the support is disposed.

15. The electric vehicle drive of claim 10, further comprising a connector system providing contiguous EMI shielding for conductors coupled between the power electronics circuit and external circuitry.

16. The electric vehicle drive of claim 10, wherein the support is cooled to remove heat from the power electronics circuit during operation.

17. The electric vehicle drive of claim 16, wherein the support includes inlet and outlet ports and a coolant circulation path therebetween.

18. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a power electronics circuit;

an EMI shielding assembly including a support incorporating integral EMI shielding features that include a flange at least partially surrounding the support, and at least partially defining an electrical reference plane, and an enclosure at least partially surrounding the support and electrically coupled to the reference plane, the shielding assembly providing contiguous shielding having intrinsically low impedance paths for EMI originating from the power electronics circuit and from sources external to the shield assembly during operation;

low impedance conductive paths for EMI at connections to the EMI shielding assembly and power electronics circuit; and

a connector system providing contiguous EMI shielding for conductors coupled between the power electronics circuit and external circuitry.

19. The electric vehicle drive of claim 18, wherein the support is a single-piece support.

20. The electric vehicle drive of claim 18, wherein the enclosure comprises a metallic cover.

21. The electric vehicle drive of claim 18, wherein the enclosure includes a canister in which the support is disposed.

22. The electric vehicle drive of claim 18, wherein the enclosure includes a multi-piece housing in which the support is disposed.

23. The electric vehicle drive of claim 18, wherein the support is cooled to remove heat from the power electronics circuit during operation.

24. The electric vehicle drive of claim 23, wherein the support includes inlet and outlet ports and a coolant circulation path therebetween.

25. An electric drive for a vehicle at least partially propelled by an electric motor, the drive comprising:

a vehicle drive train;

a power converter operatively coupled to the drive train and comprising;

a cooled support at least partially defining an electrical reference plane, and having a base extending generally in a plane and an integral flange portion extending from the plane and at least partially surrounding a component mounting area;

a power electronics circuit supported on the support within the component mounting area; and

an enclosure at least partially surrounding the support and electrically coupled to the reference plane, wherein the enclosure provides contiguous EMI shielding to the power electronic circuit and is electrically contiguous with the cooled support;

wherein the support and the integral flange at least partially shield electromagnetic interference originating from the power electronics circuit during operation.

26. The electric vehicle drive of claim 25, wherein the EMI shielding enclosure includes a canister in which the support is disposed.

27. The electric vehicle drive of claim 25, wherein the EMI shielding enclosure includes a multi-piece housing in which the support is disposed.

28. The electric vehicle drive of claim 25, wherein the shielding enclosure includes a connector system providing contiguous EMI shielding with conductors coupled between the power electronics circuit and external circuitry.

29. The electric vehicle drive of claim 25, wherein the support includes inlet and outlet ports and a coolant circulation path therebetween.