Power converter having improved fluid cooling

• US 7,187,548 B2
• Filed: 12/23/2002
• Issued: 03/06/2007
• Est. Priority Date: 01/16/2002
• Status: Expired due to Fees

• 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., Radosevich, Lawrence D., Meyer, Andreas A., Beihoff, Bruce C.
• Primary Examiner(s): THOMPSON, GREGORY D
• Application Number:
  US10/252,318
• Publication Number:
  US 20030151893A1
• Time in Patent Office: 1,534 Days
• Field of Search: None
• US Class Current: 361/699
• 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

A 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, which may be controlled in a closed-loop manner. Interfacing between circuits, circuit mounting structure, and the support provide for greatly enhanced cooling. 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. A modular power converter comprising:

a power electronics circuit configured to generate controlled output power; and

an electrical and thermal subassembly to which the power electronics circuit is directly mounted, the subassembly including a fluid diverting means to direct cooling fluid into contact with a interface on which the power electronics circuit is supported and a flow regulating element to provide regulation of temperature of the power electronics circuit in a closed-loop manner.

2. The modular power converter of claim 1, wherein the power electronics circuit includes solid state switches configured to bi-directionally or uni-directionally convert incoming power to controlled outgoing power.

3. The modular power converter of claim 2, wherein a first portion of the power electronics circuit is supported on a first side of the subassembly and a second portion of the power electronics circuit is supported on a second side of the subassembly opposite the first side.

4. The modular power converter of claim 1, wherein the subassembly includes 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.

5. The modular power converter of claim 4, comprising an interface on which the power electronics circuit is secured, the interface contacting cooling fluid flowing through the internal fluid conduit during operation to convectively and conductively remove heat from the power electronics circuit.

6. The modular power converter of claim 5, wherein the interface includes a plate supporting a plurality of solid state switches or power conversion devices directly secured thereto.

7. The modular power converter of claim 6, wherein the solid state switches or power conversion devices are bonded to the plate.

8. The modular power converter of claim 6, wherein the solid state switches or power conversion devices are mechanically mounted to the interface.

9. The modular power converter of claim 5, wherein the interface includes a plurality of heat exchange surfaces extending into the internal fluid conduit.

10. The modular power converter of claim 9, wherein the heat exchange surfaces are generally pin shaped.

11. The modular power converter of claim 5, wherein the fluid diverting means includes a diverter disposed within the internal fluid conduit to control flow of cooling fluid.

12. The modular power converter of claim 5, further comprising a heat exchanging element disposed in the internal fluid conduit.

13. The modular power converter of claim 12, wherein the heat exchanging element is secured to the interface.

14. The modular power converter of claim 5, wherein the interface is removably secured to the subassembly.

15. The modular power converter of claim 1, further comprising a flow control valve for regulating flow of cooling fluid through the internal fluid conduit.

16. The modular power converter of claim 15, further comprising at least one sensor for detecting temperature of a portion of the converter, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the internal fluid conduit.

17. A modular power converter support, the support comprising:

a substrate having inlet and outlet ports and a circulation path coupled between the inlet and outlet ports, the inlet and outlet ports being configured to transmit a coolant for circulation through the circulation path, the substrate being made of a first material;

an interface plate configured to directly support a power electronics circuit and to be secured to the substrate, the interface plate having integral heat dissipation elements extending therefrom configured to extend into the coolant circulation path when the interface plate is mounted to the substrate for extraction of heat from the interface plate during operation, the interface plate being made of a second material different from the first material;

a flow control valve for regulating flow of cooling fluid through the coolant circulation path; and

at least one sensor for detecting temperature, wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the coolant circulation path.

18. The support of claim 17, comprising a plurality of interface plates configured to be secured to the substrate and to contact coolant circulating therethrough during operation.

19. The support of claim 18, wherein the substrate is configured to receive the interface plates on different sides thereof.

20. The support of claim 19, wherein the different sides include mutually opposed sides of the substrate.

21. The support of claim 17, wherein the interface plate supports a plurality of solid state switches bonded thereto.

22. The support of claim 17, wherein the interface plate includes a plurality of heat exchange surfaces extending into the internal fluid conduit.

23. The support of claim 22, wherein the heat exchange surfaces are generally pin shaped.

24. The support of claim 22, wherein the substrate includes a plurality of heat exchange surfaces configured to cooperate with the heat exchange surfaces of the interface plate for heat transfer.

25. The support of claim 24, wherein the heat exchange surfaces of the interface plate and of the substrate are generally pin shaped.

26. The support of claim 17, further comprising a diverter disposed within the coolant circulation path to control flow of cooling fluid therethrough.

27. The support of claim 26, wherein the diverter directs flow of cooling fluid into toward the interface plate.

28. The support of claim 17, further comprising a heat exchanging element disposed in the coolant circulation path.

29. The support of claim 28, wherein the heat exchanging element is secured to the interface plate.

30. The support of claim 17, wherein the interface plate is removably secured to the substrate.

31. A modular power converter comprising:

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

a fluid cooled support for supporting at least the power electronics circuit, 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

an interface on which the power electronics circuit is secured, the interface contacting cooling fluid flowing through the internal fluid conduit during operation to convectively remove heat from the power electronics circuit; and

wherein the fluid cooled support includes a fluid diverting means to direct cooling fluid into contact with the interface.

32. The modular power converter of claim 31, wherein the interface includes a plate supporting a plurality of solid state switches bonded thereto.

33. The modular power converter of claim 31, wherein the interface includes a plurality of heat exchange surfaces extending into the internal fluid conduit.

34. The modular power converter of claim 33, wherein the heat exchange surfaces are generally pin shaped.

35. The modular power converter of claim 33, wherein the support includes a plurality of heat exchange surfaces configured to cooperate with the heat exchange surfaces of the interface for heat transfer.

36. The modular power converter of claim 35, wherein the heat exchange surfaces of the interface and of the support are generally pin shaped.

37. The modular power converter of claim 31, wherein the fluid diverting means includes a diverter disposed within the internal fluid conduit to control flow of cooling fluid therethrough.

38. The modular power converter of claim 33, further comprising a heat exchanging element disposed in the internal fluid conduit.

39. The modular power converter of claim 38, wherein the heat exchanging element is secured to the interface.

40. The modular power converter of claim 33, wherein the interface is removably secured to the support.

41. The modular power converter of claim 33, further comprising a flow control valve coupled to the support for regulating flow of cooling fluid through the internal fluid conduit.

42. The modular power converter of claim 41, further comprising a sensor for detecting temperature of a portion of the converter, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the internal fluid conduit.

43. A modular power converter comprising:

a plurality of controlled power electronics circuits including solid state switches configured to convert incoming power to controlled outgoing power;

a fluid cooled support for supporting at least the power electronics circuits, 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 circuits for removal of heat therefrom;

a plurality of interfaces on which the respective power electronics circuits are secured, the interfaces contacting cooling fluid flowing through the internal fluid conduit during operation to convectively remove heat from the power electronics circuit; and

a diverter disposed within the internal fluid conduit to control flow of cooling fluid therethrough.

44. The modular power converter of claim 43, wherein the power electronic circuits are supported on opposing sides of the support.

45. The modular power converter of claim 44 wherein each interface includes a plate supporting a plurality of solid state switches bonded thereto.

46. The modular power converter of claim 44, wherein each interface includes a plurality of heat exchange elements extending into the internal fluid conduit.

47. The modular power converter of claim 46, wherein the heat exchange elements are generally pin shaped.

48. The modular power converter of claim 43, further comprising a heat exchanging element disposed in the internal fluid conduit.

49. The modular power converter of claim 43, wherein each interface is removably secured to the support.

50. The modular power converter of claim 43, further comprising a flow control valve coupled to the support for regulating flow of cooling fluid through the internal fluid conduit.

51. The modular power converter of claim 43, further comprising at least one sensor for detecting temperature of a portion of the converter, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the internal fluid conduit.

52. A modular power converter comprising:

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

a fluid cooled support for supporting at least the power electronics circuit, 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;

an interface on which the power electronics circuit is secured, the interface contacting cooling fluid flowing through the internal fluid conduit during operation to convectively remove heat from the power electronics circuit;

a flow control valve coupled to the support for regulating flow of cooling fluid through the internal fluid conduit; and

a diverter disposed within the internal fluid conduit to control flow of cooling fluid therethrough.

53. The modular power converter of claim 52, further comprising a sensor for detecting temperature of a portion of the converter, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the internal fluid conduit.

54. The modular power converter of claim 52, wherein the interface includes a plate supporting a plurality of solid state switches bonded thereto.

55. The modular power converter of claim 52, wherein the interface includes a plurality of heat exchange surfaces extending into the internal fluid conduit.

56. The modular power converter of claim 55, wherein the heat exchange surfaces are generally pin shaped.

57. The modular power converter of claim 52, wherein the diverter directs flow of cooling fluid into contact with the interface.

58. The modular power converter of claim 52, further comprising a heat exchanging element disposed in the internal fluid conduit.

59. The modular power converter of claim 58, wherein the heat exchanging element is secured to the interface.

60. The modular power converter of claim 52, wherein the interface is removably secured to the support.

61. A modular power converter comprising:

a substrate having inlet and outlet ports and a circulation path coupled between the inlet and outlet ports, the inlet and outlet ports being configured to transmit a coolant for circulation through the circulation path, the substrate being made of a first material;

an interface plate configured to support a power electronics circuit and to be secured to the substrate, the interface plate having integral heat dissipation elements extending therefrom configured to extend into the coolant circulation path when the interface plate is mounted to the substrate for extraction of heat from the interface plate during operation, the interface plate being made of a second material different from the first material, the interface plate further including a plurality of heat exchange surfaces extending into the internal fluid conduit; and

a diverter disposed within the coolant circulation path to control flow of cooling fluid therethrough.

62. The modular power converter of claim 61, wherein the heat exchange surfaces are generally pin shaped.

63. The modular power converter of claim 61, wherein the substrate includes a plurality of heat exchange surfaces configured to cooperate with the heat exchange surfaces of the interface plate for heat transfer.

64. The modular power converter of claim 63, wherein the heat exchange surfaces of the interface plate and of the substrate are generally pin shaped.

65. The modular power converter of claim 61, comprising a plurality of interface plates configured to be secured to the substrate and to contact coolant circulating therethrough during operation.

66. The modular power converter of claim 65, wherein the substrate is configured to receive the interface plates on different sides thereof.

67. The modular power converter of claim 66, wherein the different sides include mutually opposed sides of the substrate.

68. The modular power converter of claim 61, wherein the interface plate supports a plurality of solid state switches bonded thereto.

69. The modular power converter of claim 67, wherein the diverter directs flow of cooling fluid into toward the interface plate.

70. The modular power converter of claim 61, wherein the interface plate is removably secured to the substrate.

71. The modular power converter of claim 61, further comprising a flow control valve for regulating flow of cooling fluid through the coolant circulation path.

72. The modular power converter of claim 71, further comprising at least one sensor for detecting temperature, and wherein the sensor is coupled to the flow control valve for closed loop control of flow of cooling fluid through the coolant circulation path.