Electrical device and method of assembling such an electrical device

Patent metadata

Field	Value
Publication number	US-10230288-B2
Application number	US-201615364331-A
Country	US
Kind code	B2
Filing date	Nov 30, 2016
Priority date	Dec 2, 2015
Publication date	Mar 12, 2019
Grant date	Mar 12, 2019

Abstract

The invention relates to an electrical device ( 10 ), notably intended to control an electric machine, comprising:
a first zone filled with an insulating material (A) and comprising a first electronic unit ( 12 ) embedded in the insulating material (A); a second zone filled with an insulating material (B) and comprising a second electronic unit ( 18 ) embedded in the insulating material (B); and a third zone filled with an insulating material (B) and comprising at least one electrical connection element ( 22 ) embedded in the insulating material (B), the at least one electrical connection element ( 22 ) connecting the first electronic unit ( 12 ) with the second electronic unit ( 18 );

in which the first and the second zone are each in contact with the third zone so that the electrical device comprises at least one space extending around the third zone and between the first and the second zone.

First claim

The invention claimed is:

1. An electrical device for controlling an electric machine, comprising:
a first zone filled with a first insulating material and comprising a first electronic unit embedded in the first insulating material;
a second zone filled with a second insulating material and comprising a second electronic unit embedded in the second insulating material;
a third zone filled with the second insulating material; and
an electrical connection element,
wherein the electrical connection element is embedded in its entirety by a combination of the first insulating material and the second insulating material,
wherein the electrical connection element connects the first electronic unit with the second electronic unit,
wherein the first zone and the second zone are each in contact with the third zone so that the electrical device comprises at least one space extending around the third zone and between the first zone and the second zone.

2. The electrical device according to claim 1 , in which the first, second and third zones are superposed, the first and second zones extending substantially along parallel planes.

3. The electrical device according to claim 1 , in which the third zone is defined at least in part by a hollow column into which the at least one electrical connection element is intended to be inserted, the hollow column extending between the first and the second zone.

4. The electrical device according to claim 3 , in which the hollow column is filled with the second insulating material.

5. The electrical device according to claim 3 , also comprising a support of an electronic unit, arranged between the first electronic unit and the second electronic unit and comprising an open cavity intended to receive the second electronic unit.

6. The electrical device according to claim 5 , in which the hollow column extends from the open cavity and is configured to communicate with the open cavity at a first end of the hollow column.

7. The electrical device according to claim 6 , in which a second end of the hollow column opposite to the first end is in contact with the first insulating material in which the first electronic unit is embedded.

8. The electrical device according to claim 5 , in which the bottom of the open cavity comprises guidance elements for guiding the at least one electrical connection element and intended to guide the at least one electrical connection element towards the second electronic unit.

9. The electrical device according to claim 5 , further comprising;
an electrical connector configured to electrically connect the first electronic unit
to at least one of the electrical elements of an electric machine controlled by the electrical device and/or of an electrical energy source, and comprised at least in part in the space extending around the third zone and between the first and the second zone.

10. The electrical device according to claim 9 , in which the electrical connector is arranged between the first electronic unit and the support of the second electronic unit, the electrical connector comprising an orifice into which the hollow column is intended to be inserted.

11. The electrical device according to claim 1 , further comprising:
a first protective support; and
a second protective support,
wherein the first zone is covered by the first protective support;
wherein the second zone and the third zone are covered by the second protective support;
wherein the first protective support and the second protective support are distinct from each other.

12. The electrical device according to claim 1 , wherein:
the third zone is positioned immediately on top of the first zone,
the second zone is positioned immediately on top the third zone,
the first zone, second zone, and third zone are positioned in a vertical structure defined by a first protective support and a second protective support.

13. An electrical device for controlling an electric machine, comprising:
a first zone filled with a first insulating material;
a first circuit board comprising a first plurality of electronic elements,
wherein the first zone comprises the first circuit board completely surrounded by the first insulating material;

a second zone filled with a second insulating material;
a second circuit board comprising a second plurality of electronic elements,
wherein the second zone comprises the second circuit board completely surrounded by the second insulating material;

a third zone filled with the second insulating material; and
an electrical connection element,
wherein the electrical connection element connects the first circuit board with the second circuit board, and
wherein the first zone and the second zone are each in contact with the third zone so that the electrical device comprises at least one space extending around the third zone and between the first zone and the second zone.

Assignees

• Valeo Systemes De Controle Moteur

Inventors

• Tramet Guillaume
• Mas Arnaud
• Sacco Ernesto

Classifications

• H05K3/28

  Applying non-metallic protective coatings {(H05K3/0091 takes precedence; methods for intermediate insulating layers for build-up multilayer circuits H05K3/4673)} · CPC title

• H05K5/064 Primary

  sealed by potting, e.g. waterproof resin poured in a rigid casing · CPC title

• H05K2201/10189

  Non-printed connector · CPC title

• H05K7/14

  Mounting supporting structure in casing or on frame or rack · CPC title

• H05K1/144

  Stacked arrangements of planar printed circuit boards · CPC title