Ut-battelle, Inc.

Martin Marietta Energy Systems, Inc.

Lockheed Martin Energy Systems, Inc.

Curtis W Ayers

John Sheungchun Hsu

Laura D Marlino

Howard D Haynes

Chester Coomer

Gui-Jia Su

Donald Joe Adams

Donald A Casada

M Alfred Akerman

Alfred Akerman

Larry E Seiber

Andrew A Wereszczak

Kirk T Lowe

Randy H Wiles

Larry M Dickens

The disclosure describes directly cooling a three-dimensional, direct metallization (DM) layer in a power electronics device. To enable sufficient cooling, coolant flow channels are formed within the ceramic substrate. The direct metallization layer (typically copper) may be bonded to the ceramic substrate, and semiconductor chips (such as IGBT and diodes) may be soldered or sintered onto the direct metallization layer to form a power electronics module. Multiple modules may be attached to cooling headers that provide in-flow and out-flow of coolant through the channels in the ceramic substrate. The modules and cooling header assembly are preferably sized to fit inside the core of a toroidal shaped capacitor.

Direct cooled power electronics substrate

This invention teaches methods of making a hermetic terminal assembly comprising the steps of: inserting temporary stops, shims and jigs on the bottom face of a terminal assembly thereby blocking assembly core open passageways; mounting the terminal assembly inside a vacuum chamber using a temporary assembly perimeter seal and flange or threaded assembly interfaces; mixing a seal admixture and hardener in a mixer conveyor to form a polymer seal material; conveying the polymer seal material into a polymer reservoir; feeding the polymer seal material from the reservoir through a polymer outlet valve and at least one polymer outlet tube into the terminal assembly core thereby filling interstitial spaces in the core adjacent to service conduits, temporary stop, and the terminal assembly casing; drying the polymer seal material at room temperature thereby hermetically sealing the core of the terminal assembly; removing the terminal assembly from the vacuum chamber, and; removing the temporary stops, shims.

Method of making hermetic seals for hermetic terminal assemblies

The invention is a direct contact refrigerant cooling system using a refrigerant floating loop having a refrigerant and refrigeration devices. The cooling system has at least one hermetic container disposed in the refrigerant floating loop. The hermetic container has at least one electronic component selected from the group consisting of capacitors, power electronic switches and gating signal module. The refrigerant is in direct contact with the electronic component.

Refrigerant directly cooled capacitors

A cascaded die mounting device and method using spring contacts for die attachment, with or without metallic bonds between the contacts and the dies, is disclosed. One embodiment is for the direct refrigerant cooling of an inverter/converter carrying higher power levels than most of the low power circuits previously taught, and does not require using a heat sink.

Method of making cascaded die mountings with springs-loaded contact-bond options

A method for cooling vehicle components using the vehicle air conditioning system comprising the steps of: tapping the hot liquid refrigerant of said air conditioning system, flooding a heat exchanger in the vehicle component with said hot liquid refrigerant, evaporating said hot liquid refrigerant into hot vapor refrigerant using the heat from said vehicle component, and returning said hot vapor refrigerant to the hot vapor refrigerant line in said vehicle air conditioning system.

Floating loop method for cooling integrated motors and inverters using hot liquid refrigerant

A passive vehicle acoustic data analyzer system having at least one microphone disposed in the acoustic field of a moving vehicle and a computer in electronic communication the microphone(s). The computer detects and measures the frequency shift in the acoustic signature emitted by the vehicle as it approaches and passes the microphone(s). The acoustic signature of a truck driving by a microphone can provide enough information to estimate the truck speed in miles-per-hour (mph), engine speed in rotations-per-minute (RPM), turbocharger speed in RPM, and vehicle weight.

Truck acoustic data analyzer system

A floating loop vehicle component cooling and air-conditioning system having at least one compressor for compressing cool vapor refrigerant into hot vapor refrigerant; at least one condenser for condensing the hot vapor refrigerant into hot liquid refrigerant by exchanging heat with outdoor air; at least one floating loop component cooling device for evaporating the hot liquid refrigerant into hot vapor refrigerant; at least one expansion device for expanding the hot liquid refrigerant into cool liquid refrigerant; at least one air conditioning evaporator for evaporating the cool liquid refrigerant into cool vapor refrigerant by exchanging heat with indoor air; and piping for interconnecting components of the cooling and air conditioning system.

Floating loop system for cooling integrated motors and inverters using hot liquid refrigerant

Cascaded die mountings with spring-loaded contact-bond options

This disclosure provides an integrated thermal management system and methods for managing the cooling of electrical devices and components and the heating and cooling of the passengers' compartment in a hybrid or full electric vehicle to reduce the cost and volume of such systems.

Methods and apparatus for thermal management of vehicle systems and components

A wireless boundary monitor system used to monitor the integrity of a boundary surrounding an area uses at least two housings having at least one transmitting means for emitting ultrasonic pressure waves to a medium. Each of the housings has a plurality of receiving means for sensing the pressure waves in the medium. The transmitting means and the receiving means of each housing are aimable and communicably linked. At least one of the housings is equipped with a local alarm means for emitting a first alarm indication whereby, when the pressure waves propagating from a transmitting means to a receiving means are sufficiently blocked by an object a local alarm means or a remote alarm means or a combination thereof emit respective alarm indications. The system may be reset either manually or automatically. This wireless boundary monitor system has useful applications in both indoor and outdoor environments.

Wireless boundary monitor system and method

A new instrument for monitoring the condition and speed of an operating electric motor from a remote location. The slip-poles component is derived from a motor current signal. The magnitude of the slip-poles component provides the basis for a motor condition monitor, while the frequency of the slip-poles component provides the basis for a motor speed monitor. The result is a simple-to-understand motor health monitor in an easy-to-use package. Straightforward indications of motor speed, motor running current, motor condition (e.g., rotor bar condition) and synthesized motor sound (audible indication of motor condition) are provided. With the device, a relatively untrained worker can diagnose electric motors in the field without requiring the presence of a trained engineer or technician.

Instrument for analysis of electric motors based on slip-poles component

A wireless communication system undetectable by radio frequency methods for converting audio signals, including human voice, to electronic signals in the ultrasonic frequency range, transmitting the ultrasonic signal by way of acoustical pressure waves across a carrier medium, including gases, liquids, or solids, and reconverting the ultrasonic acoustical pressure waves back to the original audio signal. The ultrasonic speech translator and communication system (20) includes an ultrasonic transmitting device (100) and an ultrasonic receiving device (200). The ultrasonic transmitting device (100) accepts as input (115) an audio signal such as human voice input from a microphone (114) or tape deck. The ultrasonic transmitting device (100) frequency modulates an ultrasonic carrier signal with the audio signal producing a frequency modulated ultrasonic carrier signal, which is transmitted via acoustical pressure waves across a carrier medium such as gases, liquids or solids. The ultrasonic receiving device (200) converts the frequency modulated ultrasonic acoustical pressure waves to a frequency modulated electronic signal, demodulates the audio signal from the ultrasonic carrier signal, and conditions the demodulated audio signal to reproduce the original audio signal at its output (250).

Ultrasonic speech translator and communications system

Operability of aircraft mechanical components is monitored by analyzing the voltage output of an electrical generator of the aircraft. Alternative generators, for a turbine-driven rotor aircraft, include the gas producer turbine tachometer generator, the power turbine tachometer generator, and the aircraft systems power producing starter/generator. Changes in the peak amplitudes of the fundamental frequency and its harmonics are correlated to changes in condition of the mechanical components.

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Kingston, TN, United States of America

Curtis W Ayers