Power converter magnetics assembly

• US 9,564,266 B2
• Filed: 10/31/2014
• Issued: 02/07/2017
• Est. Priority Date: 10/31/2014
• Status: Active Grant

• Current Assignee: Raytheon Company (Rtx Corporation)
• Original Assignee: Raytheon Company (Rtx Corporation)
• Inventors: Jacobson, Boris S., Elkins, Stephen R., Jaworski, Bradley S.
• Primary Examiner(s): Haughton, Anthony
• Assistant Examiner(s): AHMAD, YAHYA A.
• Application Number:
  US14/530,014
• Publication Number:
  US 20160128235A1
• Time in Patent Office: 830 Days
• Field of Search: 361688-723, 165 41- 43
• US Class Current: 1/1
• CPC Class Codes: H01F 27/025 Constructional details relating to cooling
• 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 power converter magnetics assembly is disclosed. The power converter magnetics assembly can include an interface panel, a magnetic component mounted to the interface panel to form a magnetics subassembly, and a chassis coupled to the magnetics subassembly. The chassis can have a cavity with an opening. The magnetic component can be received within the cavity and the interface panel can be disposed over the opening and secured to the chassis to form an enclosure about the magnetic component.

Claims

1. A power converter magnetics assembly, comprising:

an interface panel;

a magnetic component mounted to the interface panel to form a magnetics subassembly; and

a chassis coupled to the magnetics subassembly, the chassis having a cavity with an opening, wherein the magnetic component is received within the cavity through the opening and the interface panel is disposed over the opening and secured to the chassis to form an enclosure about the magnetic component.

2. The power converter magnetics assembly of claim 1, wherein the chassis comprises a coolant duct.

3. The power converter magnetics assembly of claim 1, wherein the chassis comprises at least one wall with a coolant duct formed therein.

4. The power converter magnetics assembly of claim 3, wherein the at least one wall comprises a first wall with a first coolant duct and a second wall, opposite the first wall about the cavity, with a second coolant duct, such that coolant enters the cavity via the first coolant duct and exits the cavity via the second coolant duct.

5. The power converter magnetics assembly of claim 3, wherein the at least one wall comprises an inlet port on an exterior of the chassis and a plurality of outlet ports on an interior of the chassis to distribute coolant to the cavity.

6. The power converter magnetics assembly of claim 1, wherein the magnetic component comprises a frame and at least one magnetic device coupled to the frame, and wherein the frame is coupled to the interface panel.

7. The power converter magnetics assembly of claim 6, wherein the interface panel comprises at least one access port to facilitate an electrical connection of the at least one magnetic device to at least one electrical component located outside the enclosure through the interface panel.

8. The power converter magnetics assembly of claim 7, further comprising at least one termination tab electrically coupled to the at least one magnetic device to electrically couple the at least one magnetic device to the at least one electrical component located outside the enclosure.

9. The power converter magnetics assembly of claim 1, wherein the chassis comprises a mounting feature to facilitate coupling the chassis to a support structure.

10. A power converter module, comprising:

a support structure; and

a power converter magnetics assembly coupled to the support structure, the power converter magnetics assembly having

an interface panel,

a magnetic component mounted to the interface panel to form a magnetics subassembly, and

a chassis coupled to the magnetics subassembly, the chassis having a cavity with an opening, wherein the magnetic component is received within the cavity through the opening and the interface panel is disposed over the opening and secured to the chassis to form an enclosure about the magnetic component.

11. The power converter module of claim 10, wherein the support structure comprises a cold plate.

12. The power converter module of claim 11, further comprising a coolant delivery conduit thermally coupled to the cold plate and a coolant return conduit, wherein the chassis comprises a coolant duct in fluid communication with the coolant delivery conduit and the coolant return conduit to cool the magnetic component.

13. The power converter module of claim 12, further comprising at least one electrical component located outside the enclosure and supported by the support structure, wherein the magnetic component is electrically coupled to the at least one electrical component located outside the enclosure.

14. The power converter module of claim 13, wherein the at least one electrical component located outside the enclosure comprises a bus bar.

15. The power converter module of claim 14, wherein the bus bar is thermally coupled to the magnetic component to cool the bus bar.

16. A method of manufacturing a power converter magnetics assembly, comprising:

obtaining an interface panel;

obtaining a magnetic component;

obtaining a chassis having a cavity with an opening;

mounting the magnetic component to the interface panel to form a magnetics subassembly; and

coupling the magnetics subassembly to the chassis, wherein the magnetic component is received within the cavity through the opening and the interface panel is disposed over the opening and secured to the chassis to form an enclosure about the magnetic component.

17. The method of claim 16, further comprising coupling at least one magnetic device to a frame to form the magnetic component.

18. The method of claim 17, wherein mounting the magnetic component to the interface panel comprises coupling the frame to the interface panel.

19. The method of claim 16, further comprising electrically coupling at least one termination tab to at least one magnetic device of the magnetic component to facilitate an electrical connection of the at least one magnetic device to at least one electrical component located outside the enclosure through the interface panel.

20. The method of claim 19, further comprising extending the at least one termination tab at least partially through at least one access port of the interface panel to facilitate an electrical connection of the at least one magnetic device to at least one electrical component located outside the enclosure through the interface panel.