Power electronic device shell

Abstract

A system includes a housing defining an interior space surrounded by walls of the housing. The power electronics are disposed within the interior space. The power electronics may include at least one inverter configured to invert direct current (DC) power to alternating current power, at least one voltage converter for boosting a voltage from a DC source to an electrical panel voltage, at least one rectifier configured to rectify alternating current (AC) power to DC power, and at least one voltage converter for reducing the voltage from the electrical panel voltage to the battery charge level. A wall mounting feature may extend from the housing configured for mounting the housing to a wall surface. It may also be contemplated that the hinge member may extend from a wall of the housing such that the housing may be hingedly mounted to the electrical panel as a door for the electrical panel.

Description

Technical Field

[0001] This disclosure relates to power electronic devices, and more specifically to power electronic devices used with electrical panels, such as in residential applications. Background Technology

[0002] Power electronic devices for residential use (i.e., for homes, small businesses, etc.) enable homes to connect to the public power grid for alternating current (AC) power, converting between AC and direct current (DC), and converting between different voltages. Power electronic devices for applications such as electric vehicles (EVs), backup batteries, and solar panels can include inverters, rectifiers, and voltage converters. Such devices can be connected to residential electrical panels that provide power distribution to various circuits within the home and circuit protection such as circuit breakers.

[0003] One issue with power electronics used in residential applications is that several additional boxes or panels can be added in addition to the main electrical panel. This takes up space and can complicate maintenance, upgrades, and replacements. The problem with encapsulating power electronics in enclosures (such as inside the main electrical panel) is that a typical electrical panel can potentially last 50 years or more. The need to replace and rewire the entire electrical panel every time a homeowner has to replace the power electronics is a major obstacle to further integration of power electronics with the residential electrical panel.

[0004] Conventional technologies have been considered satisfactory for their intended purposes. However, there has been a persistent need for improved systems and methods for integrating power electronic devices for residential use. This disclosure provides a solution to this need. Summary of the Invention

[0005] A system includes a housing defining an internal space enclosed by walls of the housing. Power electronic devices are disposed within the internal space. Connectors extend from the power electronic devices through the walls of the housing into an external space outside the housing, for connecting the power electronic devices to external components.

[0006] Power electronic devices may include rectifiers configured to convert electrical panel power into direct current (DC) power for charging DC batteries. Power electronic devices may include voltage converters for converting electrical panel voltage into a different voltage for charging DC batteries. Power electronic devices may include inverters configured to convert DC power into alternating current (AC) power for supplying electrical panels from one or more DC sources, such as solar panels, stationary energy storage systems (ESS), electric vehicle (EV) batteries, etc. Power electronic devices may include voltage converters for converting DC source voltage into electrical panel voltage for supplying electrical panels. It is contemplated that power electronic devices may include at least one inverter configured to invert DC power into AC power, at least one voltage converter for boosting voltage from a DC source to an electrical panel voltage, at least one rectifier configured to rectify AC power into DC power, and at least one voltage converter for reducing voltage from electrical panel voltage to a battery charging level. Power electronic devices may also include transformers operatively connected to provide a neutral line during standby operation.

[0007] A wall-mounting feature may extend from the housing and is configured to mount the housing to a wall surface. A first hinge component is also contemplated to extend from the wall of the housing. The first hinge component may be configured to be hingedly connected to a second hinge component. The first hinge component may include a corresponding hinge cylinder configured to fall in and out of a corresponding hinge pin for mounting and to be lifted out of the corresponding hinge pin for removal. The first hinge component may include a corresponding hinge pin configured to fall downward into the corresponding hinge cylinder for mounting and to be lifted upward out of the corresponding hinge cylinder for removal. The connector may include a wire harness having a plug at its end for electrically connecting wires between power electronics and external components.

[0008] A system includes an electrical panel configured to distribute power among multiple load circuits. A housing defines an interior space enclosed by the walls of the housing. Power electronic devices are disposed within the interior space. Connectors extend from the power electronic devices through the walls of the housing to an exterior space outside the housing. The connectors electrically connect the power electronic devices to the interior of the electrical panel.

[0009] The interior of the electrical panel may include a corresponding circuit breaker operably connected to protect the load circuitry. An electric vehicle (EV) distributor may be operably connected to the electrical panel and power electronics for charging the EV and / or supplying power to the circuitry from the EV. Each of the housing and the electrical panel may be configured to be mounted to a wall surface. The electrical panel may be configured to be mounted to a wall surface, and the housing may be configured to be hingedly mounted to the electrical panel as a door to the electrical panel.

[0010] Power electronic devices may include at least one inverter configured to invert direct current (DC) power into alternating current (AC) power, at least one voltage converter for boosting voltage from a DC source to an electrical panel voltage, at least one rectifier configured to rectify alternating current (AC) power into DC power, and at least one voltage converter for reducing voltage from an electrical panel voltage to a battery charging level.

[0011] A first hinge component may extend from a wall of the housing. The first hinge component may include a corresponding hinge cylinder configured to rest on a corresponding hinge pin of the electrical panel. The first hinge component may extend from a wall of the housing. The first hinge component may include a corresponding hinge pin configured to drop downward into the corresponding hinge cylinder for mounting and configured to lift upward out of the corresponding hinge cylinder for removal. The connector may include a wire harness having a plug at its end for insertion into a corresponding socket on the panel for electrically connecting wires between power electronics and external components.

[0012] These and other features of the systems and methods of this disclosure will become more apparent to those skilled in the art from the following detailed description of preferred embodiments in conjunction with the accompanying drawings. Attached Figure Description

[0013] Therefore, those skilled in the art to which this disclosure pertains will readily understand how to manufacture and use the apparatus and methods of this disclosure without excessive experimentation. Preferred embodiments thereof will now be described in detail with reference to certain accompanying drawings, in which:

[0014] Figure 1 This is a schematic perspective view of an embodiment of a system constructed according to the present disclosure, showing the housing of a door configured to be hingedly mounted to an electrical panel, wherein the door is open;

[0015] Figure 2 yes Figure 1 A schematic perspective view of the system, showing the door in the closed position;

[0016] Figure 3 yes Figure 1 A schematic exploded perspective view of the system, showing the door separated from the electrical panel;

[0017] Figure 4 yes Figure 1 A schematic front view of the system, showing the instrument panel and the electric vehicle (EV) distributor connected to the electrical panel;

[0018] Figure 5 yes Figure 1 A schematic diagram of a part of the system, showing the power electronic devices inside the housing; and

[0019] Figure 6 yes Figure 1 A schematic diagram of the system shows a housing for power electronic devices configured for mounting to a wall surface rather than serving as a door. Detailed Implementation

[0020] Reference will now be made to the accompanying drawings, wherein like reference numerals identify similar structural features or aspects disclosed herein. Partial views of embodiments of the systems according to this disclosure are provided for purposes of explanation and illustration, and not limitation. Figure 1 As shown in the figures, and generally indicated by reference numeral 100. As will be described, in Figure 2-6 Other embodiments or aspects thereof of the system according to this disclosure are provided. The systems and methods described herein can be used to facilitate the installation, repair, and replacement of power electronic devices for connection to residential electrical panels.

[0021] System 100 includes an electrical panel 102 configured to distribute power among multiple load circuits. The electrical panel 102 is configured to be mounted to a wall surface. A housing 104 defines an interior space 106 (within) enclosed by walls 108 of the housing 104. Figure 3 (Marked in the middle). Power electronic device 110 is disposed in internal space 106 (in Figure 3 Inside (marked in the middle). Connector 112 extends from power electronics 110 through the wall 108 of the housing to the external space outside the housing 104. Connector 112 electrically connects power electronics 110 to the interior 114 of electrical panel 102. The interior 114 of electrical panel 102 includes a corresponding circuit breaker 116 operably connected to the interior 114 for protecting load circuits, such as various circuits distributed throughout the residence for lighting, sockets, stoves, ovens, cooktops, washing machines / dryers, air conditioners, etc. Housing 104 is configured as a door for electrical panel 102, in Figure 1 It is shown in the open position, and Figure 2 It is shown in the closed position.

[0022] Now for reference Figure 3 The door or housing 104 can be disconnected and removed from the electrical panel 102 without disconnecting the individual circuits of the circuit breaker 116, and without even opening the electrical panel 102 itself. The connector 112 includes a wire harness 118 having a plug 120 at its end for insertion into a corresponding socket 122 on the panel for, for example, electrically connecting wires between the power electronics 110 and external components via the electrical panel 102.

[0023] Hinge component 124 extends from the wall of the housing, for example, along its edge. Hinge component 124 is configured to be hingedly connected to a corresponding hinge component 126 of the electrical panel 102. Hinge components 124, 126 include corresponding hinge cylinders configured to mount onto corresponding hinge pins 128 for installation. This allows hinge components 124 and pins 128 to drop down onto / into hinge component 126 for installation and to be lifted from hinge component 126 for removal. Hinge pins 128 may be a separate component or may be permanently attached to hinge component 124 or hinge component 126. In this way, the hinges connecting housing 104 to electrical panel 102 allow for easy installation and removal. Although in Figure 1-3 The hinge is depicted on the right-hand side of the electrical panel 102, but those skilled in the art will readily understand from this disclosure that any suitable hinge arrangement can be used, for example, the hinge can be on the left-hand side, top side, or bottom side, such as... Figure 1-3 The orientation is as described, without departing from the scope of this disclosure. Furthermore, although shown as having a single door, those skilled in the art who benefit from this disclosure will readily understand that multiple doors can be used, for example, in which different portions of the power electronics 110 are mounted in different doors hinged to the electrical panel 102.

[0024] Now for reference Figure 4 System 100 may include an electric vehicle (EV) distributor 130, operatively connected to electrical panel 102 and power electronics 110, for charging the EV and / or supplying power to the circuit from the EV, such as utilizing the EV battery as a backup, altering peak usage to improve utility rates, etc. Utility meter 132 utilizes a built-in selector switch 134 (in... Figure 1 and Figure 3 The internal switch (marked in the middle) is operably connected to the electrical panel 102, and is configured to disconnect the internal 114 and all its circuitry from the utility meter 132. This allows the electrical panel 102 to supply power to the residential circuitry from battery storage or a power source such as a solar panel, wherein the electrical panel 102 is isolated or isolated from the public power grid.

[0025] Now for reference Figure 5The power electronic device 110 includes components for converting various types of power, including different current types (AC or DC) and different voltage levels. These components can allow bidirectional charging / charging from batteries such as EV batteries. For DC-to-AC conversion, the power electronic device 110 may include at least one inverter 136 configured to invert direct current (DC) power into alternating current (AC) power for supplying AC power from one or more DC sources to the electrical panel. DC sources may include power generation equipment such as solar panels, generators, etc., as well as backup batteries, stationary energy storage systems (ESS), EV batteries, etc. The power electronic device 110 may also include at least one DC-DC voltage converter 138 for converting DC source voltage to electrical panel voltage for supplying power to the electrical panel 102, for supplying power to loads in the circuitry of the electrical panel 102, or for supplying power from the electrical panel 102 to the utility grid. DC-DC voltage converter 138 can be a DC-DC converter used to increase or decrease voltage as needed, for example, to increase the voltage from a DC source (such as a solar panel, backup battery, or EV battery) to the voltage of an electrical panel.

[0026] For AC-to-DC conversion, the power electronic device may include at least one rectifier 140 configured to rectify AC power from the utility grid, for example, via electrical panel 102, into DC power. At least one voltage converter 142, such as a transformer, may be included for reducing voltage from the electrical panel voltage or otherwise converting it to a battery charging level for charging a DC battery or powering other DC loads. In the case of a transformer, it is also contemplated that the transformer may be operatively connected to provide a neutral line during standby operation.

[0027] Figure 5 The illustrated configuration includes an AC-DC conversion path or channel 146 and a DC-AC conversion path or channel 148, and thus allows for bidirectional charging. For example, a battery connected to the power electronics 110, either an EV or a backup / storage battery, can be charged by the electrical panel 102 or by the power electronics 110. Those skilled in the art will readily appreciate that, without departing from the scope of this disclosure, any suitable number of different AC-DC paths or channels can be included for providing various DC voltages, and any suitable number of different DC-AC paths or channels, for example, for providing AC power from various DC voltages.

[0028] AC-DC conversion path or channel 146 receives AC power from electrical panel 102, for example, via connector 112 into voltage converter 142 (e.g., a transformer), which in many applications reduces the voltage from the grid or panel to a suitable DC voltage for a given DC load (e.g., charging an EV battery). The output of voltage converter 142 is converted AC power, for example, at a reduced voltage, which is supplied to rectifier 140. The rectifier converts the converted AC power into DC power at the correct voltage level for output to a DC device or battery via connector 112.

[0029] DC-AC conversion path or channel 148 accepts DC power from an electrical panel, for example, via connector 112 to a DC-DC voltage converter 138, such as a boost converter, which in many applications increases the voltage from a DC source (such as a solar panel or battery) to a suitable AC voltage, for example, to power the circuitry of electrical panel 102. The output of DC-DC voltage converter 138 is converted DC power, which is supplied to inverter 136. Inverter 136 converts the converted DC power into AC power at a desired voltage (e.g., grid or panel voltage). This can be supplied to electrical panel 102, for example, from power electronics 110 via connector 112. Although shown as four separate components, DC-DC voltage converter 138, inverter 136, voltage converter 142, and rectifier 140 can be combined or separated as individual components. For example, power electronics 110 may include a single component that accepts a DC input and outputs an AC voltage at a desired output voltage, for example, a combined DC-DC converter / inverter device. It is also anticipated that the power electronics 110 need not be bidirectional and may include only a single power electronics component, such as a single inverter, a single rectifier, or a single voltage converter.

[0030] Now for reference Figure 6 We can also imagine that, in addition to Figure 1 and Figure 3 The hinge component numbered 124 is either outside or replaced. Figure 1 and Figure 3 The hinge component 124, numbered 124, may include a wall-mounting feature 144 extending from the wall 108 of the housing 104. The wall-mounting feature 144 is configured to mount the housing 104 and the electrical panel 102 to a wall surface, for example, together with the electrical panel 102, the instrument cluster 132, and the EV distributor 130, as... Figure 6 As shown. In this configuration, the electrical panel 102 may include a panel door 150 that is separate from the housing 104.

[0031] This disclosure provides a home or residential electrical panel packaged with power conversion hardware. All power conversion devices can be located on the panel's door or in a housing mounted to a wall surface, such as near the panel. This provides ease of installation and maintenance. Typically, home panels can last over 50 years, and the lifespan of various power electronics components can be much shorter. By keeping the power conversion devices on a door or a separate housing, homeowners can continue to upgrade the panel with new doors or separate housings without having to replace the main panel each time. Furthermore, in the event of a failure, the door or housing can be replaced individually without disrupting the home or residential load.

[0032] Power electronics can be encapsulated in housings as disclosed herein to reduce heat dissipation, weight, size, and heat generation, while still maintaining the door's NEMA 4X rating. Hinge systems as disclosed herein allow for easy door installation and will be able to support the door's weight. Cable management systems as disclosed herein help ensure that cables extending from the door to the panel are easily managed and not caught, allowing for easy door opening. Cable management systems ensure that cables are not caught when the door is closed, which could otherwise lead to a short circuit. Power electronics can be encapsulated to help reduce the size and weight of the door and ensure that the door is not too heavy for the hinges while still meeting functional requirements. Reducing the size of the door or the individual housing helps ensure that the panel and power electronics do not occupy too much space on the wall surface.

[0033] The systems and methods disclosed herein can provide potential benefits including the following: They can allow for a central controller concept for complex systems, thereby reducing system control and communication complexity; they can reduce installation time because they provide movable and installable components; they can reduce system downtime; they allow power electronic converters to be located on doors or installed separately. Panels are also expected to be placed on doors. The systems and methods disclosed herein can allow users to use smart components in two different locations because they only need to remove the door; the systems and methods disclosed herein can also use a multi-door concept, for example, where part of a door is common in the application (such as an inverter), and another door can be removed if needed. The systems and methods disclosed herein also allow for better thermal management because the door or panel can have active thermal management (e.g., fan or liquid cooling systems). Panels can be configured for flush mounting or surface mounting, thus providing flexibility for the end user.

[0034] The methods and systems of this disclosure, as described above and in the accompanying drawings, provide convenient installation, repair, and replacement of power electronic devices for connection to residential electrical panels. While the devices and methods of this subject matter disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily understand that changes and / or modifications can be made thereto without departing from the scope of this subject matter disclosure.

Claims

1. A system comprising: An outer casing, the outer casing defining an internal space surrounded by the walls of the outer casing; A power electronic device, wherein the power electronic device is disposed within the internal space; and A connector extending from the power electronic device through the wall of the housing to an external space outside the housing, for connecting the power electronic device to an external component.

2. The system according to claim 1, wherein, The power electronic device includes a rectifier configured to convert electrical panel power into direct current (DC) power for charging a DC battery.

3. The system according to claim 2, wherein, The power electronic device includes a voltage converter for converting electrical panel voltage into different voltages for charging a DC battery.

4. The system according to claim 1, wherein, The power electronic device includes an inverter configured to convert direct current (DC) power into alternating current (AC) power for supplying electrical panels from one or more DC sources.

5. The system according to claim 4, wherein, The power electronic device includes a voltage converter for converting a DC source voltage into an electrical panel voltage for supplying power to the electrical panel.

6. The system according to claim 1, wherein, The power electronic device includes: At least one inverter, the at least one inverter being configured to invert direct current (DC) power into alternating current (AC) power; At least one voltage converter for boosting a voltage from a DC source to an electrical panel voltage; At least one rectifier, said at least one rectifier being configured to rectify alternating current (AC) power into DC power; and At least one voltage converter for reducing the voltage from the electrical panel voltage to the battery charging level.

7. The system of claim 1 further includes a wall-mounting feature extending from the housing, the wall-mounting feature being configured to mount the housing to a wall surface.

8. The system of claim 1, further comprising a first hinge member extending from a wall of the housing, wherein, The first hinge component is configured to be hingedly connected to the second hinge component.

9. The system according to claim 8, wherein, The first hinge component includes a corresponding hinge cylinder configured to descend onto a corresponding hinge pin for mounting and to rise from the corresponding hinge pin for removal.

10. The system according to claim 8, wherein, The first hinge component includes a corresponding hinge pin, which is configured to fall downward into a corresponding hinge cylinder for installation and to be lifted upward out of the corresponding hinge cylinder for removal.

11. The system according to claim 1, wherein, The connector includes a wire harness with a plug at its end for electrically connecting wires between the power electronic device and the external component.

12. A system comprising: An electrical panel configured to distribute power among multiple load circuits; An outer casing, the outer casing defining an internal space surrounded by the walls of the outer casing; A power electronic device, wherein the power electronic device is disposed within the internal space; and A connector extending from the power electronic device through the wall of the housing to an external space outside the housing, wherein the connector electrically connects the power electronic device to the interior of the electrical panel.

13. The system according to claim 12, wherein, The electrical panel includes internally operably connected circuit breakers for protecting the load circuit.

14. The system according to claim 12, wherein, The power electronic device includes a transformer operatively connected to provide a neutral line during standby operation.

15. The system of claim 12, wherein each of the housing and the electrical panel is configured to be mounted to a wall surface.

16. The system according to claim 12, wherein, The electrical panel is configured to be mounted to a wall surface, and the housing is configured to be hingedly mounted to the electrical panel as a door to the electrical panel.

17. The system according to claim 16, wherein, The power electronic device includes: At least one inverter, the at least one inverter being configured to invert direct current (DC) power into alternating current (AC) power; At least one voltage converter for boosting a voltage from a DC source to an electrical panel voltage; At least one rectifier, said at least one rectifier being configured to rectify alternating current (AC) power into DC power; and At least one voltage converter for reducing the voltage from the electrical panel voltage to the battery charging level.

18. The system of claim 16, further comprising a first hinge member extending from a wall of the housing, wherein, The first hinge component includes a corresponding hinge cylinder configured to be mounted on a corresponding hinge pin of the electrical panel.

19. The system of claim 16, further comprising a first hinge member extending from the wall of the housing, wherein, The first hinge component includes a corresponding hinge pin, which is configured to fall downward into a corresponding hinge cylinder for installation and to be lifted upward out of the corresponding hinge cylinder for removal.

20. The system according to claim 12, wherein, The connector includes a wire harness with a plug at its end for insertion into a corresponding socket on the panel to electrically connect the power electronics and the external components.

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