Fishtail packaging and cooling
A combined battery charger and motor driver circuit assembly includes a plurality of power transistors arranged as a planar array, a cold plate configured to couple heat from each of the transistors in the array, a conductive power coupling fitting (also termed a bus bar), at least one capacitor, and a ferrite bead filter surrounding a necked section of the bus bar. The bus bar has a plurality of individually electrically conductive layers, each two of the layers being separated by an insulating layer, each conductive layer providing a plurality of contacts, the contacts in a layer configured to provide electrical contact, in the alternative, for power transistor collectors or power transistor emitters. The laminated bus bar is extended to form a fishtail shape along a specified section distal to the power transistors. The fish tail section terminates in two electrical contacts configured to provide electrical contact via discrete conductors to respective positive and negative battery terminals. A top surface of the capacitor is conductive at least in part. The capacitor makes electrical and thermal contact with a conductor of the laminated bus bar distal to the transistor array. A bottom surface of the capacitor is also conductive at least in part and is in electrical contact with a conductor of the laminated bus bar proximal to the transistor array.
1. A device comprising:
a plurality of power transistors, arranged as a planar array;
a cold plate, configured to couple heat from each of the transistors in the array;
a generally flat conductive power coupling fitting, also termed herein a bus bar, having a plurality of individually electrically conductive layers, each two of the layers being separated by an insulating layer, each conductive layer providing a plurality of contacts, the contacts in a layer configured to provide electrical contact, in the alternative, for power transistor collectors or power transistor emitters, said bus bar being necked along a specified section thereof distal to the power transistors, the necked section terminating in two electrical contacts configured to provide electrical contact via discrete conductors to respective positive and negative battery terminals;
at least one capacitor, whereof a top surface, conductive at least in part, makes electrical and thermal contact with a conductor of said bus bar distal to the transistor array, and a bottom surface, conductive at least in part, makes at least electrical contact with an adapter bracket that makes electrical contact with a conductor of said bus bar proximal to the transistor array; and,
said bus bar is in physical and thermal contact with said cold plate.
2. The device of claim 1 further comprising a ferrite bead filter surrounding the necked section of the bus bar.
3. The circuit assembly of claim 1 , further comprising an X/Y filter subassembly positioned so that two terminals of the X/Y subassembly can be captured between contacts on the discrete conductors and the terminating electrical contacts of the bus bar, where between at least one capacitor is connected, the X/Y subassembly further having at least one additional terminal configured for attachment to an available ground contact provided as a packaging element, and the X/Y subassembly further having at least one capacitor connected from a positive terminal to ground and at least one capacitor connected from a negative terminal to ground.
4. The device of claim 1 , wherein at least a portion of the necked section of the bus bar has a tapered width measured along a transverse axis.