Immersion cooled motor controller

Patent metadata

Field	Value
Publication number	US-9414520-B2
Application number	US-201313903127-A
Country	US
Kind code	B2
Filing date	May 28, 2013
Priority date	May 28, 2013
Publication date	Aug 9, 2016
Grant date	Aug 9, 2016

Abstract

An immersion cooled motor controller assembly is disclosed that includes a sealed housing, a fluorocarbon cooling liquid contained in the sealed housing, and an AC/AC motor controller disposed in the sealed housing and submerged in the fluorocarbon cooling liquid, wherein the AC/AC motor controller includes a power board module adapted and configured to operate at power levels greater than 30 kW.

First claim

What is claimed is:

1. An immersion cooled motor controller assembly comprising:
a) a sealed housing with finned heat sinks are provided on exterior surfaces of the housing;
b) a non-conductive cooling liquid including a fluorocarbon contained in the housing; and
c) a motor controller disposed in the housing and submerged in the non-conductive cooling liquid, the motor controller including:
a power board module configured to operate at power levels that are greater than 30 kW, the power board module including:
a printed wire board;
a bank of closely packed, power semiconductor switches coupled to the printed wire board;
a bank of DC link capacitors mounted to the printed wire board; and
active rectifier gate drive circuitry mounted to the printed wire board and operatively connected to the power semiconductor switches;

a bank of differential mode inductors adjacent to the printed wire board; and
a bank of common mode inductors adjacent to the printed wire board,
wherein the differential mode inductors and common mode inductors are constructed from 14 AWG wire.

2. An immersion cooled motor controller assembly as recited in claim 1 , wherein a low density filler material is disposed within the housing to reduce the volume of cooling liquid contained therein.

3. An immersion cooled motor controller assembly as recited in claim 1 , wherein each of the power semiconductor switches includes an individual clip-on heat sink to increase the surface area available for cooling.

4. An immersion cooled motor controller assembly as recited in claim 1 , wherein the motor controller further includes a filter board module and a control board module.

5. An immersion cooled motor controller assembly comprising:
a) a sealed housing with interior and exterior finned heat sinks,
wherein the interior finned heat sinks are provided on lower, upper, and lateral surfaces of interior surfaces of the sealed housing;

b) a fluorocarbon cooling liquid contained in the sealed housing; and
c) a motor controller disposed in the sealed housing and submerged in the fluorocarbon cooling liquid to facilitate nucleated cooling of electronic components of the motor controller, the motor controller including a power board module, having:
a printed wire board;
a plurality of closely packed, vertically mounted power semiconductor switches coupled to the printed wire board;
a bank of DC link capacitors mounted to the printed wire board; and
active rectifier gate drive circuitry mounted to the printed wire board and operatively connected to the power semiconductor switches;

a bank of differential mode inductors adjacent to the printed wire board; and
a bank of common mode inductors adjacent to the printed wire board,
wherein the differential mode inductors and common mode inductors are constructed from 14 AWG wire;
wherein the motor controller has a power density of about 1 kW/lb and/or a volumetric power density of 77 kW/ft 3 .

6. An immersion cooled motor controller assembly as recited in claim 5 , wherein each semiconductor switch has an individual heat sink operatively associated therewith to increase the surface area available for cooling.

7. An immersion cooled motor controller assembly as recited in claim 5 , wherein a low density plastic filler material is disposed within the sealed housing to reduce the volume of cooling liquid contained therein.

8. An immersion cooled motor controller assembly as recited in claim 5 , wherein the motor controller further includes a filter board module and a control board module.

9. An immersion cooled motor controller assembly as recited in claim 5 , wherein the power board module is adapted and configured to operate at power levels greater than 30 kW.

10. An immersion motor controller assembly as recited in claim 5 , further including upper and lower EMI shield plates disposed within the sealed interior and isolating the common mode inductors and differential mode inductors from the power control module.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Campbell Kris H
• Courtney Christopher J
• Parkin Joshua Scott
• Shepard Charles

Classifications

• H05K7/203

  by immersion · CPC title

• H05K7/20936

  Liquid coolant with phase change · CPC title

• H05K7/20236 Primary

  by immersion · CPC title

• H05K7/20927

  Liquid coolant without phase change · CPC title