Systems, methods, and mechanical designs for inverters for eVTOL aircraft

Patent metadata

Field	Value
Publication number	US-12351325-B2
Application number	US-202418761099-A
Country	US
Kind code	B2
Filing date	Jul 1, 2024
Priority date	Oct 6, 2022
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

An electrical propulsion system for a vertical take-off and landing (VTOL) aircraft comprises an electrical motor assembly and an inverter assembly. The inverter assembly comprises a housing, a capacitor assembly, at least one printed circuit board assembly (PCBA), and a plurality of positioning pins. The capacitor assembly comprises a center hole, at least one capacitor, a capacitor housing having at least one busbar, and a plurality of through holes in the capacitor housing. The capacitor assembly and the at least one PCBA are positioned inside the housing. The plurality of positioning pins pass through the through the plurality of through holes of the capacitor housing and the at least one PCBA and are connected to the housing.

First claim

What is claimed is:

1. An inverter assembly that converts direct current (DC) power to alternate current (AC) power for an electrical propulsion system, the inverter assembly comprising:
at least one printed circuit board assembly (PCBA);
a capacitor assembly including:
at least one capacitor; and
a capacitor housing having at least one busbar; and
a housing, wherein the capacitor assembly and the at least one PCBA are positioned inside the housing, wherein the inverter assembly has a center hole extending through the capacitor assembly and the at least one printed circuit board assembly, the center hole having a central axis which is substantially parallel with a main shaft of the electric propulsion system.

2. The inverter assembly of claim 1 , wherein the electrical propulsion system is a vertical take-off and landing (VTOL) aircraft electrical propulsion system.

3. The inverter assembly of claim 2 , wherein the center hole is configured to receive a pitch control shaft coupled to a variable pitch mechanism of the vertical take-off and landing (VTOL) aircraft electrical propulsion system.

4. The inverter assembly of claim 3 , wherein the variable pitch mechanism is configured to adjust a propeller blade pitch of the vertical take-off and landing (VTOL) aircraft electrical propulsion system.

5. The inverter assembly of claim 1 , wherein the central axis of the center hole is substantially aligned with the main shaft of the electrical propulsion system.

6. The inverter assembly of claim 1 , wherein the at least one PCBA and the capacitor assembly are stacked.

7. The inverter assembly of claim 6 , wherein the at least one PCBA comprises a gate drive PCBA and a power PCBA, and wherein the capacitor assembly is positioned between the gate drive PCBA and the power PCBA.

8. The inverter assembly of claim 7 , wherein at least a portion of the power PCBA abuts at least a portion of the capacitor assembly.

9. The inverter assembly of claim 1 , wherein:
the center hole of the capacitor assembly is a through hole, and
the inverter assembly has a substantially doughnut shape.

10. The inverter assembly of claim 1 , wherein the at least one busbar is positioned outside the capacitor housing.

11. The inverter assembly of claim 1 , further comprising:
a control board with low voltage (LV) logic input;
an electromagnetic interference (EMI) shield; and
a heat exchanger;
wherein the control board and the EMI shield are positioned inside the housing; and
wherein the heat exchanger is outside the housing.

12. The inverter assembly of claim 11 , wherein the heat exchanger is coupled to a thermal plate.

13. The inverter assembly of claim 11 , wherein the heat exchanger is configured to cool the inverter assembly using fluid.

14. The inverter assembly of claim 13 , wherein the fluid is oil.

15. The inverter assembly of claim 1 , wherein the at least one capacitor is a ring capacitor.

16. The inverter assembly of claim 1 , wherein the at least one PCBA comprises a flexible PCBA structure.

17. An electrical propulsion system for a vertical take-off and landing (VTOL) aircraft, the electrical propulsion system comprising:
a propeller assembly;
an electrical motor assembly including at least a stator and a rotor, wherein the electrical motor assembly drives the propeller assembly through a main shaft,
an inverter assembly positioned on a different end of the main shaft than the propeller assembly, the inverter assembly comprising:
at least one printed circuit board assembly (PCBA);
a capacitor assembly including:
at least one capacitor; and
a capacitor housing having at least one busbar; and
a housing, wherein the capacitor assembly and the at least one PCBA are positioned inside the housing, wherein the inverter assembly has a center hole extending through the capacitor assembly and the at least one printed circuit board assembly, the center hole having a central axis which is substantially parallel with the main shaft.

18. The electrical propulsion system of claim 17 , further comprising:
a gearbox assembly, wherein the electrical motor is positioned between the gearbox assembly and the propeller assembly, wherein the main shaft extends through the gearbox assembly.

19. The electrical propulsion system of claim 17 , wherein the inverter assembly and the propeller assembly are positioned on opposite ends of the main shaft.

20. The electrical propulsion system of claim 17 , further comprising a heat exchanger disposed outside of the housing, wherein the heat exchanger is configured to cool the inverter assembly using a fluid.

Assignees

• Archer Aviation Inc

Inventors

• Tepe Alan D
• Zwiers Michael

Classifications

• H02K7/116

  with gears · CPC title

• H02P27/06

  using DC to AC converters or inverters (H02P27/05 takes precedence) · CPC title

• H02P25/00

  Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details · CPC title

• H02M7/003

  Constructional details, e.g. physical layout, assembly, wiring or busbar connections · CPC title

• H02M7/44

  by static converters · CPC title