Method of assembling an electric power

• US 7,197,819 B1
• Filed: 12/18/2004
• Issued: 04/03/2007
• Est. Priority Date: 12/18/2004
• Status: Active Grant

• Current Assignee: Rinehart Motion Systems, LLC (BorgWarner Incorporated)
• Original Assignee: Rinehart Motion Systems, LLC (BorgWarner Incorporated)
• Inventors: Rinehart, Lawrence E., Romero, Guillermo L.
• Primary Examiner(s): Tugbang; A. Dexter
• Assistant Examiner(s): NGUYEN, TAI V
• Application Number:
  US11/016,602
• Time in Patent Office: 836 Days
• Field of Search: 298/32, 298/54, 298/40, 298/60, 298/31, 174/537, 174/536, 174/50.52, 174/50.54, 361/743, 361/699, 361/520, 361/514, 228/180.1, 228/180.21, 228/180.5, 439/76.1, 439/76.2, 439/75, 439/83
• US Class Current: 29/840
• CPC Class Codes: H01L 23/473 by flowing liquids H01L23/4332, H01L23/4338 take precedence
• CPC Class Codes: H01L 25/072 the devices being arranged next to each other
• 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: H05K 7/1432 specially adapted for power drive units or power converters
• CPC Class Codes: H05K 7/14329 specially adapted for the configuration of power bus bars
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49144 by metal fusion
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor

Abstract

A method of assembling and providing an electric power apparatus. The method uses a heat resistant housing having a structure adapted to accommodate and retain a power circuit card and also including a bracket adapted to accommodate and constrain a rigid conductive member. A power circuit card having an electrical terminal is placed into the housing and a rigid conductive member into the bracket. The rigid conductive member is flow soldered to the electrical terminal, thereby exposing the heat resistant housing to heat and creating a solder bond. Finally, the rigid conductive member is affirmatively connected to the housing. The bracket constrains the rigid conductive member so that the act of affirmatively connecting does not weaken the solder bond.

Claims

1. A method of assembling and providing an electric power apparatus:

(a) providing a heat resistant housing having a structure adapted to accommodate and retain a power circuit card and also including a bracket adapted to accommodate and constrain a rigid conductive member;

(b) providing a power circuit card having an electrical terminal;

(c) placing said power circuit card into said housing;

(d) placing a rigid conductive member into said bracket; and

(e) flow soldering said rigid conductive member to said electrical terminal, thereby exposing said heat resistant housing to heat and creating a solder bond;

(f) affirmatively connecting said rigid conductive member to said housing, wherein said bracket constrains said rigid conductive member so that said act of affirmatively connecting does not weaken said solder bond.

2. The method of claim 1, wherein said rigid conductive member defines an aperture and said bracket defines a threaded hole, and wherein said rigid conductive member is affirmatively connected to said housing by placing a screw through said aperture and fastening said screw into said threaded hole, thereby applying torque to said rigid conductive member, said rigid conductive member being constrained by said bracket so that said torque does not cause a lateral force to be placed on said solder bond, said bracket thereby preventing said act of fastening said screw from weakening said solder bond.

3. The method of claim 1 further comprising releasing said electrical power apparatus to a customer and permitting said bracket to constrain said rigid conductive member during customer use.