Cooled electrical terminal assembly and device incorporating same

• US 20050018386A1
• Filed: 08/25/2004
• Published: 01/27/2005
• Est. Priority Date: 01/16/2002
• Status: Active Grant

• Current Assignee: Bruce C. Beihoff, Daniel G. Kannenberg, Dennis L. Kehl, Lawrence D. Radosevich, Mark G. Phillips, Steven C. Kaishian
• Original Assignee: Bruce C. Beihoff, Daniel G. Kannenberg, Dennis L. Kehl, Lawrence D. Radosevich, Mark G. Phillips, Steven C. Kaishian
• Inventors: Kehl, Dennis L., Kannenberg, Daniel G., Kaishian, Steven C., Radosevich, Lawrence D., Beihoff, Bruce C., Phillips, Mark G.
• Granted Patent: US 7,095,612 B2
• Time in Patent Office: Days
• 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 terminal assembly comprising:

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 terminal assembly of claim 1, wherein the body is made of a ceramic-filled thermoplastic.

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

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

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

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

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

9-31. -31. (canceled).

32. A power and signal input and output termination system for a modular power converter comprising:

a thermal support; and

an electrically isolating but thermally conducting terminal element supported on the thermal support and carrying conductors and cooling the conductors via heat transfer to the thermal support.

33. The termination system of claim 32, wherein the terminal element comprises a integral structure removably secured to the thermal support.

34. The termination system of claim 32, wherein the terminal element includes an electrically insulative body in which the conductors are secured.

35. The termination system of claim 32, wherein the terminal assembly includes a two incoming power conductors and three outgoing power conductors.

36. The termination system of claim 35, wherein the incoming power conductors are disposed between respective outgoing power conductors.

37. The termination system of claim 32, wherein the terminal element comprises an electrically insulative and thermally conductive polymer.

38. The termination system of claim 32, wherein the terminal element includes integral connection pads for interconnecting the terminal element with the power converter circuit.

39. The termination system of claim 32, wherein the terminal element is directly mounted adjacent to an edge of the support.

40-64. -64. (canceled).

65. A power and signal input and output termination system for a modular power converter comprising:

an electrically isolating but thermally conducting terminal element comprising an electrically insulative and thermally conductive polymer supported on the thermal support and carrying conductors and cooling the conductors via heat transfer to the thermal support.

66. The termination system of claim 65, wherein the cooling element includes a conduit for routing a cooling fluid through at least a portion of the body.

67. The termination system of claim 65, wherein the cooling element includes a thermal extension for conducting heat from the body.

68. The termination system of claim 65, wherein the terminal element includes a two incoming power conductors and three outgoing power conductors.