Liquid-cooled PCB for inductive power transfer and inverter electronics

Abstract

A liquid-cooled PCB for inductive power transfer and inverter electronics is provided. A printed circuit board holder for rotary applications, comprising: a printed circuit board holder configured to be mechanically attached to a rotor shaft of an electric motor at an inner diameter surface, having at least one fluid channel extending from the inner diameter surface to an outer diameter surface; a printed circuit board mechanically attached to the plane of the holder, where the printed circuit board has a thermally conductive layer in contact with the printed circuit board holder; a component mounted to the printed circuit board such that the component is positioned over the at least one fluid channel, and wherein thermal energy generated by the component is conducted from the component via the thermally conductive layer to a fluid within the at least one fluid channel.

Description

Technical Field

[0001] This disclosure generally relates to electric vehicle motors and battery systems, and more specifically to a method and apparatus comprising a novel housing having integrated cooling pathways for printed circuit boards in a power electronics system within a separately energized motor. Background Technology

[0002] Electric vehicles (EVs) use electric motors to convert electrical energy from batteries into mechanical energy to turn the wheels. Generally, there are two main types of electric motors used in EVs: induction motors and permanent magnet synchronous motors (PMSMs). Induction motors are the most common type of electric motor used in EVs. They are relatively simple and inexpensive to manufacture. Induction motors are also very efficient and can provide high torque output. PMSMs are more expensive than induction motors, but they are also more efficient and offer better performance. PMSMs are typically used in high-performance EVs, such as sports cars and racing cars. Modern EVs usually have two electric motors, one per axle, but some EVs may have a single motor under the hood, or four motors, one per wheel.

[0003] While EV motors are typically driven by three-phase alternating current converted from direct current (DC) voltage supplied by the vehicle battery, a separately excited motor (SEM) is a type of motor in which the stator windings and armature windings are powered by separate voltage sources. The excitation current and armature current in the SEM can be individually adjusted, enabling precise control of the motor's performance. By changing the excitation current, the motor speed can be adjusted over a wide range. The motor can generate high torque at low speeds, making it suitable for applications requiring high starting torque or frequent speed changes. This allows for independent control of the excitation current and armature current, providing greater flexibility in adjusting the motor's speed and torque. The use of SEM technology in EVs is anticipated. Furthermore, other desirable features and characteristics of this disclosure will become apparent from the following detailed description and appended claims, taking into account the accompanying drawings and the foregoing technical and background information. Summary of the Invention

[0004] This document discloses vehicle control methods and systems, as well as associated electrical systems for providing vehicle propulsion systems, methods for manufacturing such systems, and methods for operating such systems, and motor vehicles and other equipment such as aircraft, trucks, buses, forklifts, construction vehicles, and other electric vehicles equipped with battery-powered electric motors. Various embodiments of the systems are presented by way of example, not limitation, to provide a novel housing having integrated cooling pathways for printed circuit boards in power electronic device systems within a SEM (Self-Electrical Engineering System).

[0005] According to one aspect of this disclosure, a printed circuit board holder for a rotating application includes: a printed circuit board holder configured to be mechanically attached to a rotor shaft of an electric motor, having at least one fluid channel extending from an inner diameter surface to an outer diameter surface; a printed circuit board mechanically attached to a plane of the printed circuit board holder, wherein the printed circuit board has a thermally conductive layer in contact with the printed circuit board holder; and a component mounted to the printed circuit board such that the component is positioned above the at least one fluid channel, wherein heat generated by the component is thermally conducted from the component to fluid within the at least one fluid channel via the thermally conductive layer. According to the printed circuit board holder for a rotating application, a first cross-sectional area of ​​the at least one fluid channel at the inner diameter surface is greater than a second cross-sectional area of ​​the at least one fluid channel at the outer diameter surface.

[0006] According to another aspect of this disclosure, the fluid is oil.

[0007] According to another aspect of this disclosure, the fluid is a non-conductive coolant.

[0008] According to another aspect of this disclosure, the fluid is a gas.

[0009] According to another aspect of this disclosure, the first width of at least one fluid channel is the same as the second width of the component.

[0010] According to another aspect of this disclosure, fluid is pumped into the rotor shaft and exits at a fluid port on the rotor shaft, the fluid port being aligned with an internal fluid channel port located on the inner diameter surface of the printed circuit board holder.

[0011] According to another aspect of this disclosure, at least one fluid channel has a swept-back shape.

[0012] According to another aspect of this disclosure, the printed circuit board holder is made of a non-conductive material and has at least one alignment post for aligning the printed circuit board and a plurality of retaining hooks for retaining the printed circuit board after it has been press-fitted into the printed circuit board holder.

[0013] According to another aspect of this disclosure, a method for thermally regulating a printed circuit board holder for a rotating application includes: mechanically coupling a printed circuit board holder having an inner diameter surface and an outer diameter surface to a rotor shaft such that the rotor shaft contacts the inner diameter surface, and wherein a fluid port on the rotor shaft is aligned with an internal fluid channel port on the inner diameter surface, and wherein the printed circuit board holder further includes a fluid channel extending from the internal fluid channel port to an external fluid channel port on the outer diameter surface; attaching a printed circuit board to a first edge of the printed circuit board holder such that a thermally conductive layer of the printed circuit board contacts the printed circuit board holder, and wherein a component is mounted to a surface opposite the thermally conductive layer, and wherein the component is positioned on the printed circuit board such that the component is positioned above the fluid channel.

[0014] According to another aspect of this disclosure, the edge of the printed circuit board holder is higher than the printed circuit board having components.

[0015] According to another aspect of this disclosure, the first groove in the printed circuit board holder and the second groove in the thermally conductive layer of the printed circuit board originate from a fluid channel.

[0016] According to another aspect of this disclosure, the inner diameter surface has a varying local radius such that the fluid is pressurized at the point of maximum local radius, and the point of maximum local radius is located at the port of the internal fluid channel.

[0017] According to another aspect of this disclosure, a second printed circuit board is attached to a second edge of a printed circuit board holder opposite to the printed circuit board.

[0018] According to another aspect of this disclosure, the printed circuit board includes a rectifier for converting inductively coupled alternating current into direct current to power an electromagnet.

[0019] According to another aspect of this disclosure, the first width of the fluid channel is the same as the second width of the component.

[0020] According to another aspect of this disclosure, the first cross-sectional area of ​​the fluid channel at the inner diameter surface is greater than the second cross-sectional area of ​​the fluid channel at the outer diameter surface.

[0021] According to another aspect of this disclosure, a cooling fluid flows through a fluid channel, and the cooling fluid is at least one of a gas, oil, and a dielectric coolant.

[0022] According to another aspect of this disclosure, an electric motor includes: a rotor having a plurality of electromagnets; a printed circuit board holder configured to be mechanically attached to the rotor shaft of the motor at an inner diameter surface, having a fluid passage extending from the inner diameter surface to an outer diameter surface; a printed circuit board mechanically attached to a plane of the printed circuit board holder, wherein the printed circuit board has a thermally conductive layer in contact with the printed circuit board holder; and a rectifier circuit for converting inductively coupled alternating current into direct current to power the electromagnets, wherein the rectifier circuit is mounted to the printed circuit board such that the rectifier circuit is positioned above the fluid passage, and wherein heat generated by the rectifier circuit is thermally conducted from the rectifier circuit to the fluid within the fluid passage via the thermally conductive layer.

[0023] According to another aspect of this disclosure, the first cross-sectional area of ​​the fluid channel at the inner diameter surface is greater than the second cross-sectional area of ​​the fluid channel at the outer diameter surface. Attached Figure Description

[0024] Exemplary embodiments will now be described in conjunction with the following figures, wherein the same numerals denote the same elements, and wherein:

[0025] Figure 1 Vehicles employing one or more electric vehicle motors and battery systems are shown according to various embodiments;

[0026] Figure 2 Schematic representations of EV propulsion systems according to various embodiments are shown;

[0027] Figure 3 A graphical representation of an electronic device package 300 for use on a rotor in an electric motor, according to various embodiments, is shown;

[0028] Figure 4 A graphical representation of a cross-section of a PCB retainer according to various embodiments is shown;

[0029] Figure 5 A graphical representation of a PCB retainer for use on a rotor in an electric motor, according to various embodiments, is shown;

[0030] Figure 6 A cross-sectional graphical representation of an installed PCB retainer according to various embodiments is shown. Detailed Implementation

[0031] The following detailed description is merely exemplary in nature and is not intended to limit application and use. Furthermore, it is not intended to be bound by any express or implied theory set forth in the foregoing technical fields, background art, summary of the invention, or the detailed description below. As used herein, the term "module" refers to any hardware, software, firmware, electronic control components, processing logic, and / or processor device, individually or in any combination, including but not limited to: application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), electronic circuits, processors (shared, dedicated, or grouped) and memories executing one or more software or firmware programs, combinational logic circuits, and / or other suitable components providing the described functionality.

[0032] Embodiments of this disclosure are described herein according to functional and / or logical block components and various processing steps. It should be understood that such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform specified functions. For example, embodiments of this disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which can perform various functions under the control of one or more microprocessors or other control devices. Furthermore, those skilled in the art will understand that embodiments of this disclosure can be practiced in combination with any number of systems, and the systems described herein are merely exemplary embodiments of this disclosure.

[0033] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, machine learning, image analysis, and other functional aspects of the system (and its individual operating components) are not described in detail herein. Furthermore, the connecting lines shown in the various figures included herein are intended to represent exemplary functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of this disclosure.

[0034] refer to Figure 1 The illustration shows a vehicle 10 employing one or more electric vehicle motors and battery systems, and more specifically, employing a dynamically adjustable traction inverter to minimize conduction losses using an adjustable dead time, while simultaneously preventing any shoot-through in the inverter phase legs by utilizing power devices with minimal switching time and gate charge, thus achieving a shorter dead time.

[0035] like Figure 1 As shown, vehicle 10 typically includes a chassis 12, a body 14, front wheels 16, and rear wheels 18. The body 14 is mounted on the chassis 12 and substantially surrounds the components of vehicle 10. The body 14 and chassis 12 may together form a frame. Wheels 16 and 18 are each rotatably coupled to the chassis 12 near a corresponding angle of the body 14.

[0036] In the illustrated embodiment, vehicle 10 is depicted as a passenger car; however, it should be understood that any other means of transportation may be used, including motorcycles, trucks, sports utility vehicles (SUVs), recreational vehicles (RVs), marine vessels, aircraft, etc. In various embodiments, vehicle 10 may be an autonomous vehicle that is automatically controlled to transport passengers and / or goods from one location to another. In exemplary embodiments, vehicle 10 may have a Level 2 or higher level of automation system. A Level 2 automation system represents “partial automation.” However, in other embodiments, the autonomous vehicle may be a so-called Level 3, Level 4, or Level 5 automation system. A Level 3 automation system represents conditional automation. A Level 4 system represents “high automation,” referring to the driving mode-specific performance of the automated driving system for all aspects of a dynamic driving task, even if the human driver does not respond appropriately to intervention requests. A Level 5 system represents “full automation,” referring to the full-time performance of the automated driving system for all aspects of a dynamic driving task under all road and environmental conditions that a human driver can manage.

[0037] However, it should be understood that vehicle 10 can also be a conventional vehicle without any autonomous driving capabilities. Vehicle 10 can implement the functions and methods for generating virtual views with coordinated colors according to this disclosure.

[0038] As shown, vehicle 10 typically includes a propulsion system 20, a transmission system 22, a steering system 24, a braking system 26, a sensor system 28, an actuator system 30, at least one data storage device 32, at least one controller 34, and a communication system 36. In various embodiments, the propulsion system 20 may include an internal combustion engine, an electric motor such as a traction motor, a fuel cell propulsion system, and / or combinations thereof. The transmission system 22 is configured to transmit power from the propulsion system 20 to the vehicle wheels 16 and 18 according to a selectable speed ratio. According to various embodiments, the transmission system 22 may include a step-ratio automatic transmission, a continuously variable transmission (CVT), a manual transmission, or any other suitable transmission.

[0039] Braking system 26 is configured to provide braking torque to vehicle wheels 16 and 18. In various embodiments, braking system 26 may include friction brakes, brake-by-wire brakes, regenerative braking systems such as electric motors, and / or other suitable braking systems. Steering system 24 affects the position of vehicle wheels 16 and 18. Although depicted as including a steering wheel for illustrative purposes, in some embodiments contemplated within the scope of this disclosure, steering system 24 may not include a steering wheel.

[0040] Sensor system 28 includes one or more sensing devices 40a-40n that sense observable conditions of the external and / or internal environment of vehicle 10. Sensing devices 40a-40n may include, but are not limited to, radar, lidar, global positioning system (GPS), optical cameras, thermal cameras, ultrasonic sensors, and / or other sensors. Sensing devices 40a-40n are further configured to sense observable conditions of vehicle 10. Sensing devices 40a-40n may include, but are not limited to, speed sensors, position sensors, inertial measurement sensors, temperature sensors, pressure sensors, etc.

[0041] Actuator system 30 includes one or more actuator devices 42a-42n that control one or more vehicle features, such as, but not limited to, propulsion system 20, transmission system 22, steering system 24, and braking system 26. In various embodiments, vehicle features may further include interior and / or exterior vehicle features, such as, but not limited to, doors, trunk, and cabin features, such as air, music, lighting, etc. (not numbered).

[0042] Communication system 36 is configured to wirelessly communicate information to and from other entities 48, such as, but not limited to, other vehicles (“V2V” communication), infrastructure (“V2I” communication), remote systems and / or personal devices (regarding...). Figure 2 (Described in more detail). In an exemplary embodiment, communication system 36 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using the IEEE 802.11 standard or by using cellular data communication. However, additional or alternative communication methods, such as dedicated short-range communication (DSRC) channels, are also considered to be within the scope of this disclosure. A DSRC channel refers to a one-way or two-way short-to-medium-range wireless communication channel specifically designed for automotive use and a corresponding set of protocols and standards.

[0043] Data storage device 32 stores data for functions used to automatically control vehicle 10. In various embodiments, data storage device 32 stores a defined map of the navigable environment. In addition to associated road data, the defined map may include various data, including altitude, climate, lighting, etc. In various embodiments, the defined map may be predefined by and obtained from a remote system (regarding...). Figure 2 (Further detailed description). For example, a defined map can be assembled by a remote system and transmitted to vehicle 10 (wirelessly and / or via wired means) and stored in data storage device 32. It is understood that data storage device 32 may be part of controller 34, separate from controller 34, or part of controller 34 and a separate system.

[0044] The controller 34 includes at least one processor 44 and a computer-readable storage device or medium 46. The processor 44 can be any custom or commercially available processor, central processing unit (CPU), graphics processing unit (GPU), auxiliary processor among several processors associated with the controller 34, semiconductor-based microprocessor (in the form of a microchip or chipset), macroprocessor, any combination thereof, or any device typically used for executing instructions. For example, the computer-readable storage device or medium 46 can include volatile and non-volatile storage in read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is persistent or non-volatile memory that can be used to store various operational variables when the processor 44 is powered off. The computer-readable storage device or medium 46 can be implemented using any of a number of known memory devices, such as PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combined memory device capable of storing data, some of which represents executable instructions used by the controller 34 in controlling and performing functions of the vehicle 10.

[0045] The instructions may include one or more separate programs, each including an ordered list of executable instructions for implementing logical functions. When executed by processor 44, the instructions receive and process signals from sensor system 28, execute logic, calculations, methods, and / or algorithms for automatically controlling components of vehicle 10, and generate control signals to actuator system 30 to automatically control components of vehicle 10 based on logic, calculations, methods, and / or algorithms. Although Figure 1 Only one controller 34 is shown, but embodiments of vehicle 10 may include any number of controllers 34 that communicate via any suitable communication medium or combination of communication media and cooperate to process sensor signals, perform logic, calculations, methods and / or algorithms, and generate control signals to automatically control the features of vehicle 10.

[0046] In various embodiments, one or more instructions of controller 34 are embodied in panoramic display system 100, and when executed by processor 44, process image data from at least one optical camera of sensor system 28 to extract features from the images to determine a ground plane. When executed by processor 44, the instructions use the ground plane to determine camera alignment information. The camera alignment information is then used to assemble the image data to form a surround view to customize the viewing angle. In various embodiments, sensing devices 40a to 40n include N(one or more) cameras (e.g., optical cameras configured to capture color images of the environment) that sense the external environment of vehicle 10 and generate image data. The cameras are arranged such that they each cover a specific field of view around the vehicle. For example, image data from each camera is assembled into a surround view based on the camera's attitude and position relative to the vehicle and relative to the ground.

[0047] It should be understood that controller 34 may otherwise differ from... Figure 1 The embodiments depicted herein. For example, controller 34 may be coupled to or otherwise utilize one or more remote computer systems and / or other control systems, for example, as part of one or more of the aforementioned vehicle equipment and systems. It should be understood that although this exemplary embodiment is described in the context of a full-featured computer system, those skilled in the art will recognize that the mechanisms of this disclosure can be distributed as a program product along with one or more types of non-transitory computer-readable signal-bearing media for storing the program and its instructions and for performing its distribution, such as a non-transitory computer-readable medium carrying the program and containing computer instructions stored therein for causing a computer processor (such as processor 44) to execute and implement the program. Such a program product may take many forms, and this disclosure applies equally regardless of the specific type of computer-readable signal-bearing medium used for performing the distribution. Examples of signal-bearing media include: recordable media, such as floppy disks, hard disks, memory cards, and optical disks, and transmission media, such as digital and analog communication links. It should be understood that cloud-based storage and / or other technologies may also be utilized in some embodiments. Similarly, it should be understood that the computer system of controller 34 may otherwise differ from other systems. Figure 1 In the embodiments depicted, for example, the computer system of controller 34 may be coupled to or may otherwise utilize one or more remote computer systems and / or other control systems.

[0048] Now go to Figure 2The diagram illustrates a schematic representation of an EV propulsion system 200. This schematic represents a battery 210, an inverter 220, and a drive motor 230. The battery 210 is configured to provide DC power to the inverter circuitry 220. The inverter 220 is configured to receive DC power from the battery 210 and convert the DC power into the three-phase AC current required by the motor 230. The inverter 220 rapidly switches multiple power switching devices 224 (such as transistors) in a predetermined sequence, generating a pulsating DC output. In some exemplary embodiments, filters, such as decoupling capacitors 222 placed between the power and ground pins of the inverter 220, are used to filter out noise and maintain a stable power supply voltage during switching, or one or more load capacitors or inductors are used to remove unwanted harmonics, thereby producing a clean three-phase AC waveform at the inverter 220. Each phase carries a different AC current, carefully coordinated to generate a rotating magnetic field within the motor 230. Each winding 232 in the stator of the drive motor 230 is connected to one of these three-phase currents. When current flows through winding 232, it generates a magnetic field. In drive motor 230, the rotating magnetic field from the stator interacts with winding 264 in rotor 260 of drive motor 230, which in turn generates a force according to Lenz's law. This force causes rotor 260 to attempt to align itself with the rotating magnetic field, thereby causing the motor shaft to rotate continuously. This rotating field is the driving force behind the rotation of the motor shaft, ultimately propelling the vehicle forward. The inverter's control system allows for precise manipulation of the frequency and voltage of the AC output. This fine-tuning control enables the system to precisely adjust the motor's speed and torque, ensuring smooth, efficient, and optimized operation of the EV.

[0049] While rotors 260 typically employ permanent magnets, such as neodymium magnets, electromagnetic rotors offer several distinct advantages over permanent magnet rotors in motor applications. Electromagnetic rotors 260 allow for dynamic control of the magnetic field strength. This provides greater flexibility in adjusting motor performance, such as speed, torque, and efficiency. Electromagnetic rotors 260 can be reversed, enabling the motor to operate in both directions without mechanical modifications. The ability to control the magnetic field strength allows for more precise control of the motor's characteristics, making it suitable for applications requiring fine-tuning. In some cases, electromagnetic rotors 260 can be more cost-effective than permanent magnet rotors, especially for mass production.

[0050] The electromagnetic rotor 260 receives AC power from the AC power source 252 via inductive power transfer (IPT). IPT is a technology that enables the transfer of electrical energy between two coils 254 and 255 without physical contact. For electric motors, IPT provides a solution for powering rotating components, eliminating the need for traditional conductive connections and associated maintenance burdens. AC power is applied to the transmitter coil 254, generating a time-varying magnetic field. The receiver coil 255, placed near the transmitter coil 254, experiences this magnetic field. According to Faraday's law of electromagnetic induction, a voltage is induced in the receiver coil 255. This induced voltage can be used to power one or more electromagnetic windings 264 in the rotor, among other electrical components.

[0051] Since the current induced in the receiving coil 255 is AC, it must be converted to DC to power the electromagnetic winding 264 in the rotor 260. This conversion can be performed using a rectifier 262 physically located on the rotor 260. While the rectifier 262 can be powered by the AC received from the receiving coil 255, positioning the printed circuit board in the harsh environmental conditions of the motor rotor 260 presents unique challenges for components such as cooling.

[0052] Now go to Figure 3 This illustration shows a graphical representation of an electronic component package 300 for use on a rotor in an electric motor. The exemplary electronic component package 300 includes a printed circuit board (PCB) 305 attached to a PCB holder 315. Various components 310, such as power switching components, are attached to the PCB 305. In the exemplary configuration, cooling fluid is strategically directed to each electrical component 310 based on its unique heat dissipation requirements and temperature tolerances. Integrated fluid channels within the PCB holder 315 (which also serve as mounting and orientation structures within the rotor drive shaft) facilitate efficient heat transfer. The electronic components 310 can be strategically positioned within the fluid flow path to maximize the heat transfer coefficient. The fluid flow can be carefully regulated at the outlet 330 to ensure complete component immersion while maintaining optimal flow rates. To further enhance cooling efficiency, the PCB 305 may incorporate an aluminum backing with etched or machined cooling channels. In some exemplary embodiments, the PCB 305 may be mounted externally to the rotor shaft. For example, PCB 305 can be installed in a housing that is mechanically attached to a rotor housing or an electric motor housing.

[0053] The rotational aspect of the electronic component package 300 attached to the rotor shaft presents a unique challenge for effectively cooling these various components 310 during operation. To address this challenge, the PCB holder 315 is equipped with one or more fluid channels having a channel inlet 320 and a channel outlet 330. In some exemplary embodiments, the shaft of the rotor (not shown) is positioned within the inner diameter of the PCB holder 315. The shaft may have a corresponding fluid outlet aligned with the channel inlet 320 of the PCB holder 315. Cooling fluids such as air, coolant, or oil may be introduced into the shaft, such that the coolant fluid flows from the fluid outlet, into the channel inlet 320, through the cooling channels within the PCB holder 315, and then exits from the channel outlet 330. Advantageously, this configuration concentrates the flow of cooling fluid below the various components 310, thereby cooling the components more effectively.

[0054] The innovative design of the electronic component package utilizes low thermal resistance to achieve fluid cooling of the electronic component 310. By strategically placing flow channels within the integrated PCB 305 and PCB retainer 315, heat dissipation is highly efficient, reducing the need for excess coolant or higher operating temperatures. This approach allows for potting of the electronic component 310 on one side of the PCB 305 while effectively cooling the opposite side of the PCB 305, which is beneficial for applications with high g-loads and vibration issues. The PCB retainer 315 provides additional advantages such as ease of PCB assembly, holding, potting, and handling protection, contributing to a more reliable and cost-effective cooling solution.

[0055] Now go to Figure 4 The diagram shows a graphical representation of a cross-section of a PCB retainer 400. The PCB retainer 400 is shown having fluid channels 420 extending between the inner diameter and the outer diameter of the PCB retainer 400. Each fluid channel 420 is positioned near a component 410 requiring cooling. In some exemplary embodiments, the component 410 may be positioned within a fluid flow within the fluid channel 420. Alternatively, the component 410 may be attached to the outer surface of the PCB, and a thermally conductive material may be present between the fluid channel 420 and the component 410 to facilitate cooling of the component 410.

[0056] In some exemplary embodiments, a local constraint 435 may be applied at the outlet of the passage. To optimize oil flow and coverage, the passage is widened into a funnel shape before the constraint. This design facilitates adequate oil coverage near the electronic components while limiting the overall oil flow rate. While a simple funnel shape may be effective in some exemplary embodiments, it can lead to increased energy consumption for pumping oil. By incorporating a wider passage before the constraint point, effective oil coverage and controlled flow can be achieved, potentially reducing energy expenditure.

[0057] Now go to Figure 5 A graphical representation of a PCB retainer 500 for use on a rotor in an electric motor is shown. The PCB retainer is shown having various fluid channels 520 and a rotational direction 550 when the PCB retainer 500 is mechanically coupled to the rotor shaft. In some exemplary embodiments, the fluid channels may narrow as a funnel shape from the inner diameter to the outer diameter. This narrowing can be used to regulate pressure and flow rate. In this narrowing configuration, the flow rate is regulated by the cross-sectional area of ​​the fluid channel 520 at the outer diameter. Advantageously, this configuration further ensures that the fluid channel 520 is filled with fluid during rotation, thereby maximizing heat transfer from the component to the fluid. In some exemplary embodiments, the shape of the fluid channel 520 may be adjusted, such as a curved or parabolic shape, to further regulate the flow of fluid through the fluid channel 520. In some exemplary embodiments, the narrowing of the fluid channel may occur locally at the very end of the fluid channel, allowing the fluid channel to remain wide near the component, but the restriction at the end ensures that the fluid channel is completely filled with oil.

[0058] Now go to Figure 6 The figure shows a cross-sectional graphical representation of a PCB holder 600 mounted on a rotation axis 660. The cross-sectional view illustrates a fluid channel 620 and two PCBs 640, each PCB having a thermally conductive layer 630. As shown, components 610, such as switching transistors, are mounted to the PCBs 640. In some exemplary embodiments, the PCBs 640 and the thermally conductive layer 630 may be metal-core circuit boards. In this exemplary embodiment, the thermally conductive layer 630 is directly connected to the fluid in the fluid channel 620, thereby maximizing heat transfer from the components 610 to the fluid. In some exemplary embodiments, the housing 650 may be constructed of an electrically insulating material, such as ceramic or plastic.

[0059] This exemplary PCB retainer 600 provides an innovative cooling solution for power electronics systems within high-speed SEM wireless power delivery systems. The housing 650 incorporates an integrated fluid channel 620 designed to directly contact the PCB component 610, eliminating the need for thermal interface materials and reducing thermal resistance. By optimizing channel geometry and flow rate, this design achieves efficient heat dissipation while minimizing fluid consumption. The housing 650 is designed to maintain electrical isolation, facilitate component assembly, and prevent fluid leakage, thereby ensuring a reliable and high-performance cooling system.

[0060] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the exemplary embodiments or multiple exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiments or multiple exemplary embodiments. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A printed circuit board holder for rotation applications, comprising: The printed circuit board holder is configured to be mechanically attached to the rotor shaft of the electric motor and has at least one fluid channel extending from the inner diameter surface to the outer diameter surface. A printed circuit board is mechanically attached to the plane of the printed circuit board holder, wherein the printed circuit board has a thermally conductive layer in contact with the printed circuit board holder; A component is mounted to the printed circuit board such that the component is positioned above the at least one fluid channel, and wherein heat generated by the component is thermally conducted from the component to the fluid within the at least one fluid channel via the thermally conductive layer.

2. The printed circuit board holder for rotational applications according to claim 1, wherein, The first cross-sectional area of ​​the at least one fluid channel at the inner diameter surface is greater than the second cross-sectional area of ​​the at least one fluid channel at the outer diameter surface.

3. The printed circuit board holder for rotational applications according to claim 1, wherein, The fluid is oil.

4. The printed circuit board holder for rotational applications according to claim 1, wherein, The fluid is a non-conductive coolant.

5. The printed circuit board holder for rotational applications according to claim 1, wherein, The fluid is a gas.

6. The printed circuit board holder for rotational applications according to claim 1, wherein, The first width of the at least one fluid channel is the same as the second width of the component.

7. The printed circuit board holder for rotational applications according to claim 1, wherein, The fluid is pumped into the rotor shaft and exits at a fluid port on the rotor shaft, which is aligned with an internal fluid channel port located on the inner diameter surface of the printed circuit board holder.

8. The printed circuit board holder for rotational applications according to claim 1, wherein, The at least one fluid channel has a swept-back shape.

9. The printed circuit board holder for rotational applications according to claim 1, wherein, The printed circuit board holder is made of a non-conductive material and has at least one alignment post for aligning the printed circuit board and a plurality of retaining hooks for retaining the printed circuit board after it has been press-fitted into the printed circuit board holder.

10. A method for thermally regulating a printed circuit board holder for a rotational application, comprising: The printed circuit board holder having an inner diameter surface and an outer diameter surface is mechanically coupled to a rotor shaft such that the rotor shaft contacts the inner diameter surface, and wherein a fluid port on the rotor shaft is aligned with an internal fluid channel port on the inner diameter surface, and wherein the printed circuit board holder further includes a fluid channel extending from the internal fluid channel port to an external fluid channel port on the outer diameter surface; The printed circuit board is attached to a first edge of the printed circuit board holder such that the thermally conductive layer of the printed circuit board contacts the printed circuit board holder, and wherein a component is mounted to a surface opposite the thermally conductive layer, and wherein the component is positioned on the printed circuit board such that the component is located above the fluid channel.

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