Heat transfer element with drop-shaped boss

Abstract

The present disclosure relates to an improved heat transfer element and methods for removing heat from one or more heat-generating elements (e.g., electrical components associated with systems such as motor control devices) mounted within a housing. The disclosed heat transfer element includes a plurality of fins located within a flow path. The fins increase the surface area of the heat transfer zone within the flow path, resulting in more efficient cooling by a heat transfer fluid flowing through the flow path. The heat transfer zone also includes one or more bosses. The lower sides of these bosses provide recesses for securing and mounting the heat-generating elements within the housing.In the examples described, the bosses have a drop-shaped cross-section, which improves the flow of heat transfer fluid around the bosses to result in more uniform cooling. Figure for abstract: Fig. 1.

Description

Title of the invention: Heat transfer element with drop-shaped boss

[0001] REFERENCE TO RELATED APPLICATION(S)

[0002] The present application claims the benefit of U.S. Provisional Patent Application No. 63 / 552,052, filed February 9, 2024, which is incorporated herein by reference in its entirety.

[0003] BACKGROUND OF THE INVENTION

[0004] Electrical and mechanical components, for example, electrical components associated with motor control devices, and other types of equipment can generate heat. Overheating of such equipment / elements can negatively impact the performance, function, reliability, and / or structure of the heat-generating elements or other surrounding equipment. These heat-generating elements are often installed or mounted within cabinets or other enclosures or housings, making heat removal even more difficult. A heat transfer element that can efficiently and uniformly remove heat from one or more heat-generating elements mounted within an enclosure is desired. Summary of the invention

[0005] The present disclosure relates to an improved heat transfer element and methods for removing heat from one or more heat generating elements (e.g., electrical components) mounted within a housing. The disclosed heat transfer element includes a plurality of fins located within a flow path of a heat transfer region / zone. The fins increase the surface area of ​​the heat transfer zone within the flow path, resulting in more efficient cooling by a heat transfer fluid flowing through the flow path. The heat transfer zone also includes one or more bosses. The lower sides of these bosses provide recesses for securing and mounting the heat generating elements within the housing.In the examples described, the bosses have a drop-shaped cross-section, which improves the flow of heat transfer fluid around the bosses to result in more uniform cooling.

[0006] The purpose of this summary is to present, in a simplified form, a selection of concepts which are described in more detail below in the detailed description. This summary is not intended to identify key features or essential characteristics of the claimed subject matter, nor to limit the scope of the claimed subject matter. Brief description of the drawings

[0007] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0008] [Fig.l] is a top perspective view of an exemplary motor control device assembly, according to one example.

[0009] [Fig.2] is a top perspective view of the exemplary motor control device assembly of [Fig.l] with a fan and cover removed.

[0010] [Fig. 3] is a bottom perspective view of the exemplary motor control device assembly of [Fig. 1].

[0011] [Fig.4] is a bottom perspective view of the exemplary motor control device assembly of [Fig.l], with the electrical components and associated fasteners removed.

[0012] [Fig.5] is a top view of the exemplary motor control device assembly of [Fig.l].

[0013] [Fig.6] is a first end view of the exemplary motor control device assembly of [Fig.1].

[0014] [Fig.7] is a second end view of the exemplary motor control device assembly of [Fig.l].

[0015] [Fig.8] is a partial cross-sectional view of a heat transfer area of ​​the exemplary motor control device assembly of [Fig.l].

[0016] [Fig.9] is a partial top view of a heat transfer area of ​​the exemplary motor control device assembly of [Fig.l].

[0017] [Fig.10A] is a schematic top view of a first embodiment of a drop-shaped boss of a heat transfer area of ​​the exemplary motor control device assembly of [Fig.1].

[0018] [Fig.lOB] is a schematic top view of a second embodiment of a drop-shaped boss of a heat transfer area of ​​the exemplary motor control device assembly of [Fig.l].

[0019] [Fig. 1 IA] is an example of a flow diagram of an example circular boss.

[0020] [Fig. 1 IB] is an example flow diagram of an example shortened teardrop boss.

[0021] [Fig. 1 IC] is an exemplary flow diagram of an exemplary elongated drop-shaped boss.

[0022] [Fig. 11D] is an exemplary flow diagram of an exemplary drop-shaped boss of the heat transfer area of ​​the exemplary motor controller assembly of [Fig.l].

[0023] [Fig. 12] is an example of a method of cooling one or more heat-generating components, according to the example. DETAILED DESCRIPTION

[0024] In the following detailed description, reference is made to the accompanying drawings which are a part thereof, and in which are shown, by way of illustration, specific embodiments or examples. These aspects may be combined, other aspects may be used and structural modifications may be made without departing from the present disclosure. The examples may be in the form of methods, systems, or devices. The following detailed description is therefore not to be construed in a limiting sense, and the scope of the present disclosure is defined by the appended claims and their equivalents.

[0025] Apart from any included working examples or any other indication, all numbers expressing quantities, conditions, dimensions or other measurements used herein are to be understood as modified in all cases by the term "about". The term "about" when used herein in connection with numerical values ​​means ± 20% and with percentages means ± 2%.

[0026] Motor control devices and other types of electrical and mechanical equipment can generate heat. Overheating of these heat-generating elements / components can negatively impact the performance, function, reliability, and / or structure of the heat-generating components or other surrounding equipment; therefore, it is advantageous to keep the heat-generating components below a damaging temperature. Such heat-generating elements / components are often installed or mounted within cabinets, boxes, or other enclosures, which impede heat removal or dissipation. Adding heat transfer elements to these systems (e.g., to an enclosure) can add complexity to the system and may increase the weight of the system.In some applications (e.g., aerospace applications), it is desired to minimize the total weight of overall systems and thus of the elements of those systems, while maintaining function and structural integrity.

[0027] The present disclosure relates to an improved heat transfer region / zone and methods of removing heat from one or more heat generating elements (e.g., motor control devices) mounted within a housing / enclosure. In some examples, the heat generating elements are mounted within a wall of a housing / enclosure by the use of fasteners such as screws or bolts. The enclosure wall thickness may be determined to provide structural integrity, specific safeguards (e.g., to meet industry standards, to be explosion-proof, etc.), to provide heat transfer, and / or to minimize weight. If the enclosure wall thickness is greater, structural integrity may be improved, but heat transfer capabilities may decrease and weight will increase. If the enclosure wall thickness is less, heat transfer capabilities may increase and weight will decrease, but the structural integrity of the enclosure may be reduced.In some examples, the fasteners used to mount / connect / secure the heat generating elements within the enclosure may be longer than the wall thickness; the length of the fasteners may be determined based on a length necessary to adequately secure the elements. To accommodate the length of the fasteners, a boss may protrude from an external side of the enclosure. The wall thickness of the boss may be determined based on minimizing weight, ensuring the structural integrity of the protruding boss, and ensuring a secure connection of the fastener.

[0028] Heat generated by the heat generating elements is transferred to the wall of the housing. To improve heat removal from the housing (and thus the heat generating elements themselves), a heat transfer element is positioned on the exterior of the housing, opposite the location on the interior of the housing where the heat generating elements are mounted. A heat transfer medium flows through one or more flow paths defined by aspects of the heat transfer element, to remove heat from the wall of the housing. In some examples, the heat transfer fluid is a gas, such as air, and such a gas may be driven along the one or more flow paths by a fan or similar machine.In some examples, the heat transfer fluid is a liquid, such as water, and such liquid may be driven along the flow path(s) via a pump or similar machine.

[0029] The footprint size of the heat transfer element on the exterior housing surface may be determined to provide adequate heat removal (in some examples, to at least cover the footprint of the installed heat generating element(s), minimize weight, and maintain structural integrity.

[0030] To increase the heat removal surface area, fins are located within the heat transfer element. The fins define channels through which the heat transfer fluid can flow. Although a greater number of fins and fins with geometries whose size maximizes the surface area may be advantageous for heat transfer, other factors (such as weight, fluid dynamics, manufacturability / machinability, and structural integrity) are also analyzed to determine the characteristic features of the fins and the channels they define. In addition, the width and length of the channels defined between the fins may be selected to improve heat transfer and flow characteristics. For example, for a channel volume that is larger, for a given mass flow rate of heat transfer fluid, the fluid velocity will be slower, and the heat removal rate may be slower in some examples. However, too small a channel volume may restrict the volume of heat transfer fluid flow, which may impede heat removal.In some examples, a balance is achieved between a number of fins that maximizes the surface area for heat transfer and associated channels that do not restrict the flow of the heat transfer fluid.

[0031] As the heat transfer element is positioned on the housing opposite the installed heat generating elements, one or more protruding bosses may be located within the heat transfer element. These bosses may interrupt one or more of the fins and may have a channel around their perimeter through which the heat transfer fluid may flow. In the described examples, the bosses have a teardrop-shaped cross-section / footprint, which enhances the flow of the heat transfer fluid around the bosses to result in improved cooling. The teardrop-shaped bosses have a rounded end and a tail. The rounded end is oriented toward the flow inlet and the tail end is oriented toward the flow outlet. The tail may be pointed or may have a second, smaller, rounded portion.The size and shape of the boss may be determined based on fluid dynamics and heat transfer. For example, a round boss (or a boss of another shape or size that is not preferred) may result in an area of ​​low or stagnant flow downstream of the boss, resulting in hot spots where less heat transfer occurs. Such an area may further prove problematic in an embodiment where the heat transfer fluid is a liquid, as low pressure areas downstream of a non-preferred boss may cause cavitation, which may result in physical damage.A drop-shaped boss having a preferred shape and dimensions may allow the heat transfer fluid to flow in a manner that does not result in a weak or stagnant flow area downstream, resulting in more efficient and uniform heat transfer (and, in the case of a liquid heat transfer fluid, preventing conditions that lead to cavitation).

[0032] To further improve the cooling and flow dynamics of the heat transfer fluid, in some examples where a plurality of bosses are located within the heat transfer element, the bosses may be aligned in one or more rows parallel to the fins.

[0033] The sizes and dimensions of the bosses, fins, and other features described herein may be manufactured by machining, casting, additive manufacturing, another suitable form of manufacturing, or a combination of manufacturing processes.

[0034] These and other examples will be explained in more detail below with respect to [Fig.l] to [Fig.12].

[0035] In accordance with the principles of this disclosure, [Fig. 1] illustrates a top perspective view of an exemplary motor control assembly 10. Although the particular examples illustrated are for a motor control assembly with a motor control and associated electrical components mounted within a housing, other examples of the described features may apply to other heat-generating elements / components mounted within an enclosure. The motor control assembly 10 includes a motor control housing 12 that includes a heat transfer element / heat transfer zone / heat transfer region 22 on an exterior surface 30. The heat transfer zone 22 is defined on two sides by a pair of parallel sidewalls 20 that extend from the exterior surface 30.The heat transfer zone 22 is further defined by a cover 14 that extends over the heat transfer zone 22 and is connected to the pair of side walls 20. Each of the side walls 20 may include a plurality of connecting members 18. In some examples, the connecting members 18 may include recesses or receiving members for fasteners 16 for connecting the cover 14 to the side walls 20. The fasteners 16 may include screws, nails, bolts, tacks, rivets, or other members. In other examples, the cover 14 may be connected to the side walls 20 by gluing, welding, brazing, or other connecting means. In some examples, the cover 14 may be removably connected to the side walls 20.The heat transfer zone 22 may be further defined by a flow inlet end 26 and an opposing flow outlet end 28.

[0036] In some examples, a heat transfer fluid flows through the heat transfer zone 22. In some examples, the heat transfer fluid is a gas, such as air or another suitable gas. In some examples, the heat transfer fluid is a liquid, such as water (e.g., deionized water or another type of water), a heat transfer oil, or another suitable liquid. In In some examples, a machine such as the fan 24 is connected to the housing 12 (e.g., removably or permanently mounted thereon) at the flow inlet end 26 to drive the heat transfer fluid through the heat transfer zone 22. In examples where the heat transfer fluid is a gas, the machine may be a fan 24 as shown in the particular example or a compressor. In examples where the heat transfer fluid is a pump, the machine may be a pump or other means of providing a head of liquid. Refer also to: [Fig. 6], which illustrates a first end / inlet end view of the exemplary motor controller assembly 10; and [Fig. 7], which illustrates a second end / outlet end view of the exemplary motor controller assembly 10.

[0037] [Fig.2] illustrates a top perspective view of the exemplary motor control device assembly 10, with a fan 24 and a cover 14 removed. The housing 12 has a flow inlet opening to allow the heat transfer fluid to flow into the flow inlet end 26 of the heat transfer zone 22. In some examples, the heat transfer fluid first flows through a flow inlet volume 40 defined by the housing 12 and the sidewalls 20. The cover 14 may also extend above the flow inlet volume 40. A plurality of heat transfer fins 34 extend from the exterior surface 30. The fins 34 are positioned parallel to the sidewalls 20. In some examples, the fins 34 have a uniform length, width, and / or height.In some examples, the fins 34 may have different lengths, widths, and / or heights. In some examples, the fins 34 are interrupted at one or more locations by one or more bosses 36. The bosses 36 extend from the surface 30 into the heat transfer zone 22. In some examples, the bosses are teardrop-shaped (e.g., droplet-shaped or teardrop-shaped) in cross-section parallel to the outer surface 30. In other examples, the bosses 36 may have a round, oval, elliptical, rectangular, square, semicircular, or other shaped cross-section. Although six bosses 36 are illustrated in the particular example shown, other numbers of bosses are possible in other examples.

[0038] [Fig. 3] illustrates a bottom perspective view of the exemplary motor control device assembly 10. One or more electrical components 44 may be connected or mounted to an interior surface 42 of the housing 12. The electrical components 44 are mounted on the interior surface 42 opposite the heat transfer area 22, such that heat generated by the electrical components 44 is transferred through the housing 12 and to the elements in the heat transfer area. heat transfer fluid 22 and removed by the heat transfer fluid. The electrical components 44 may be mounted to the interior surface 42 by one or more fasteners 46. The fasteners 46 may include screws, nails, bolts, tacks, rivets, or other elements. In some examples, the fasteners 46 may be used in conjunction with a coiled locking insert or similar element that fits within the recesses 48 (described below). In some examples, electrical components 44 may be removably mounted to the interior surface 42. Although three electrical components 44, each having two fasteners 46, are illustrated in the particular example shown, other numbers of electrical components 44 having other numbers of fasteners 46 are possible in other examples.

[0039] [Fig. 4] illustrates a bottom perspective view of the exemplary motor controller assembly 10 with the electrical components 44 and associated fasteners 46 removed. The interior surface 42 has one or more fastener recesses 48 that protrude into the underside of the bosses 36, which are located above the recesses 48. The recesses 48 are positioned and sized to receive the fasteners 46 to facilitate mounting of the electrical components 44 to the interior surface 42.

[0040] [Fig. 5] illustrates a top view of the exemplary motor control device assembly 10. The space between each of the fins 34 is a flow channel 50, through which the heat transfer fluid can flow. Around the perimeter of each boss 36 is a boss flow channel 56, through which the heat transfer fluid can flow. The boss flow channels 56 and the flow channels 50 define at least a portion of a flow path (which can be interpreted as a number of possible flow paths) for the heat transfer fluid to flow through the heat transfer zone 22 from the flow inlet end 26 to the flow outlet end 28.In a particular example, the heat transfer fluid may flow along a flow path FP1 through the flow inlet opening 38, through the flow inlet volume 40, and through one or more flow channels 50 (to exit the heat transfer zone 22 at the flow outlet end 28). In another particular example, the heat transfer fluid may flow along a flow path FP2 through the flow inlet opening 38, through the flow inlet volume 40, through one or more flow channels 50, and through all or part of one or more boss flow channels 56 (to exit the heat transfer zone 22 at the flow outlet end 28). In passing through these flow paths, the heat transfer fluid absorbs . heat energy from the surfaces of the flow channels 50, 56 (e.g., the bosses 36, the outer surface 30, the side walls 20, the fins 34 and / or the cover 14).

[0041] Referring now to [Fig. 7], which illustrates a second end / outlet end view of the exemplary motor controller assembly 10, the heat transfer area may also include a flow space 32, which is a volume above the fins 34 and below the cover 14. The height of the flow space 32 may be determined by the location of a sidewall shoulder 54. In some examples, the height of the sidewall shoulder 54 is equal to the height of the fins 34. In some examples, the flow path(s) of the heat transfer fluid may include flow through the flow space 32 in addition to / instead of one or more of the flow channels 50, 56.

[0042] [Fig. 8] illustrates a partial cross-sectional view of a heat transfer zone 22 of the exemplary motor control device assembly 10.

[0043] In some examples, a fin height FH (e.g., extending over the outer surface 30) is determined to maximize heat transfer and / or minimize weight. The FH may be equal to the length of the sidewall 20 that rests below the shoulder 54. In one example, all of the fins 34 have the same height. In some examples, the bosses 36 have a height equal to that of the FH. In such examples, the FH may be determined at least in part based on a length of fastener 46 needed to securely mount the electrical components 44. In other examples, the bosses 36 have a height greater or less than the FH. In one example, the FH is equal to about 0.433 inches. In some examples, the FH is equal to about 0.4 inches. In some examples, the FH is equal to about 0.3 inches. In some examples, the FH is equal to approximately 0.5 inches.In some examples, the FH is about 0.75 inches. In some examples, the FH is about 1 inch. In some examples, the FH is between about 0.4 inches and about 0.5 inches. In some examples, the FH is between about 0.2 inches and about 1.0 inches. In some examples, the FH is between about 0.3 inches and about 0.5 inches. In some examples, the FH is between about 0.4 inches and about 0.45 inches. In some examples, the FH is greater than about 0.433 inches. In some examples, the FH is greater than about 0.4 inches. In some examples, the FH is greater than about 0.2 inches. In some examples, the FH is greater than about 0.3 inches. In some examples, the FH is greater than about 1 inch. In some examples, the FH is less than about 0.433 inches. In some examples, the FH is less than about 0.45 in. In some examples, the FH is . less than about 0.5 inches. In some examples, the FH is less than about 0.3 inches. In some examples, the FH is less than about 1 inch.

[0044] In some examples, the fin width FW (e.g., the thickness of the fins 34) is determined to maximize heat transfer, provide adequate structural integrity of the fins 34, and / or minimize weight. In some examples, the FW may be equal for all fins 34. In one example, the FW is about 0.08 inches. In some examples, the FW is about 0.06 inches. In some examples, the FW is about 0.04 inches. In some examples, the FW is about 0.10 inches. In some examples, the FW is about 0.20 inches. In some examples, the FW is between about 0.08 inches and about 0.10 inches. In some examples, the FW is between about 0.01 inches and about 0.10 inches. In some examples, the FW is between about 0.06 inches and about 0.10 inches. In some examples, the FW is between about 0.07 inches and about 0.09 inches.In some examples, the FW is greater than about 0.08 inches. In some examples, the FW is greater than about 0.04 inches. In some examples, the FW is greater than about 0.06 inches. In some examples, the FW is greater than about 0.20 inches. In some examples, the FW is less than about 0.08 inches. In some examples, the FW is less than about 0.09 inches. In some examples, the FW is less than about 0.10 inches. In some examples, the FW is less than about 0.06 inches. In some examples, the FW is less than about 0.20 inches.

[0045] In some examples, a fin length FL (refer to [Fig. 5]) (e.g., extending from a flow inlet end 26 of the heat transfer zone 22 to a flow outlet end 28) is determined to maximize heat transfer and / or minimize weight. The FL may be equal to the length of the fins 34 that are not interrupted by a boss 36. In one example, the FL is equal to about 12.16 inches. In some examples, the FL is less than about 12 inches. In some examples, the FL is less than about 10 inches. In some examples, the FL is less than about 6 inches. In some examples, the FL is less than about 4 inches. In some examples, the FL is less than about 14 inches. In some examples, the FL is less than about 16 inches. In some examples, the FL is less than about 18 inches.In some examples, the FL is less than about 24 inches. In some examples, the FL is greater than about 12 inches. In some examples, the FL is greater than about 10 inches. In some examples, the FL is greater than about 6 inches. In some examples, the FL is greater than about 4 inches. In some examples, the FL is greater than about 14 inches. In some examples, the . FL is greater than about 16 inches. In some examples, the FL is greater than about 18 inches. In some examples, the FL is greater than about 24 inches. In some examples, the FL is between about 11.5 inches and about 12.5 inches. In some examples, the FL is between about 11 inches and about 13 inches. In some examples, the FL is between about 10 inches and about 14 inches. In some examples, the FL is between about 6 inches and about 18 inches. In some examples, the FL is between about 6 inches and about 13 inches. In some examples, the FL is between about 11 inches and about 18 inches.

[0046] In some examples, the flow area width FAW (refer to [Fig. 5]) (e.g., the width between the parallel sidewalls 20) is determined to maximize heat transfer, align opposite the mounted electrical components 44, and / or minimize weight. In one example, the FAW is about 4.28 inches. In some examples, the FAW is about 4 inches. In some examples, the FAW is about 5 inches. In some examples, the FAW is about 3.28 inches. In some examples, the FAW is about 5.28 inches. In some examples, the FAW is about 2 inches. In some examples, the FAW is about 8 inches. In some examples, the FAW is greater than about 4 inches. In some examples, the FAW is greater than about 5 inches. In some examples, the FAW is greater than about 2 inches.In some examples, the FAW is greater than about 3 inches. In some examples, the FAW is less than about 4 inches. In some examples, the FAW is less than about 5 inches. In some examples, the FAW is less than about 12 inches. In some examples, the FAW is less than about 7 inches. In some examples, the FAW is between about 4.28 inches and about 5.28 inches. In some examples, the FAW is between about 3.28 inches and about 4.28 inches. In some examples, the FAW is between about 3.28 inches and about 5.28 inches. In some examples, the FAW is between about 4 inches and about 5 inches. In some examples, the FAW is between about 2 inches and about 7 inches.

[0047] In some examples, the flow channel width FCW (e.g., the width of the flow channels 50 between the fins 34) is determined to maximize heat transfer and optimize the flow of the heat transfer fluid. In some examples, the FCW may be equal for all of the flow channels 50. In one example, the FCW is about 0.13 inches. In some examples, the FCW is about 0.1 inches. In some examples, the FCW is about 0.2 inches. In some examples, the FCW is about 0.05 inches. In some examples, the FCW is about 0.5 inches. In some examples, the FCW is greater than about 0.05 inches. In some examples, the FCW is greater than about 0.1 inches. In some examples, the FCW is less than about 0.2 inches. In some examples, the FCW is greater than about 0.5 inches. In some examples, the FCW is between about 0.05 inches and about 0.5 inches. In some examples, the FCW is between about 0.1 inches and about 0.2 inches. In some examples, the FCW is between about 0.05 inches and about 1 inch.

[0048] In some examples, a drop / boss flow channel width DFW (e.g., oriented around the perimeter of a boss 36) is determined to maximize heat transfer and optimize the flow of heat transfer fluid. In some examples, the DFW is determined to fit a tool (e.g., a bit, drill, or other manufacturing tool) of a standard size. The DFW may be equal for all boss flow channels 56. In one example, the DFW may be equal to the FCW. In one example, the DFW may be greater or less than the FCW. In one example, the DFW is about 0.25 inches. In some examples, the DFW is about 0.2 inches. In some examples, the DFW is about 0.3 inches. In some examples, the DFW is about 0.1 inches. In some examples, the DFW is equal to approximately 0.5 inches.In some examples, the DFW is greater than about 0.2 inches. In some examples, the DFW is greater than about 0.3 inches. In some examples, the DFW is greater than about 0.1 inches. In some examples, the DFW is greater than about 0.5 inches. In some examples, the DFW is greater than about 1 inch.

[0049] In some examples, the flow gap height FGH (e.g., the distance between the shoulder 54 and an overall height of the sidewalls 20, where the sidewall height is greater than the FH and the height of the shoulder 54 is equal to the FH) is determined to maximize heat transfer, optimize the flow of the heat transfer fluid, and ensure the structural integrity of the sidewalls 20. In one example, the FGH is about 0.067 inches. In some examples, the FGH is about 0.06 inches. In some examples, the FGH is about 0.07 inches. In some examples, the FGH is about 0.1 inches. In some examples, the FGH is about 0.05 inches. In some examples, the FGH is greater than about 0.06 inches. In some examples, the FGH is greater than about 0.07 inches. In some examples, the FGH is greater than about 0.01 inch.In some examples, the FGH is greater than about 0.05 inches. In some examples, the FGH is less than about 0.06 inches. In some examples, the FGH is less than about 0.07 inches. In some examples, the FGH is less than about 0.1 inches. In some examples, the FGH is less than about 0.05 inches. In some examples, the FGH is less than about 0.1 inches. In some examples, the FGH is between about 0.05 inches and about 0.08 inches. In some examples, the FGH is between about 0.01 inches and about 0.1 inches. In some examples, the FGH is between about 0.06 inches and about 0.06 inches.

[0050] In some examples, a drop / bump width DW (e.g., the width of a bump 36 at its widest point, equal to twice a droplet radius, as described in [Fig. 10A] and 10B) is determined at least in part by a recess diameter RD and a bump wall thickness BT.

[0051] In some examples, a recess diameter RD (e.g., the diameter of the recess 48 that receives the fasteners 46 of the motor controller) is determined to accommodate a fastener 46 that will securely mount the electrical components 44. In one example, the RD is about 0.178 inches. In some examples, the RD is about 0.1 inches. In some examples, the RD is about 0.2 inches. In some examples, the RD is about 0.05 inches. In some examples, the RD is about 0.3 inches. In some examples, the RD is greater than about 0.1 inches. In some examples, the RD is greater than about 0.2 inches. In some examples, the RD is greater than about 0.05 inches. In some examples, the RD is greater than about 0.01 inches. In some examples, the RD is less than about 0.1 inches. In some examples, the RD is less than about 0.2 inches.In some examples, the RD is less than about 0.5 inches. In some examples, the RD is less than about 1 inch. In some examples, the RD is between about 0.01 inches and about 1 inch. In some examples, the RD is between about 0.1 inches and about 0.2 inches.

[0052] In some examples, a wall thickness of the boss BT (e.g., a wall thickness of the material of the boss 36 around the recess 48) is determined so as to ensure the structural integrity of the boss 36 and / or to minimize weight. The wall thickness of the boss may vary from the rounded portion of the boss to the tail portion of the boss (see [Fig. 9]), and BT as described in this paragraph refers to a wall thickness where the outer surface of the boss 36 is equal to the drop / boss radius DR1 as described below in [Figs. 10A] and 10B. In one example, BT is equal to about 0.11 inches. In some examples, BD is equal to about 0.1 inches. In some examples, BD is equal to about 0.2 inches. In some examples, BD is equal to about 0.05 inches. In some examples, the BD is equal to approximately 0.3 inches. In some examples, the BD is greater than approximately 0.1 inches.In some examples, the BD is greater than about 0.2 inches. In some examples, the BD is greater than about 0.05 inches. In . In some examples, the BD is greater than about 0.01 inches. In some examples, the BD is less than about 0.1 inches. In some examples, the BD is less than about 0.2 inches. In some examples, the BD is less than about 0.5 inches. In some examples, the BD is less than about 1 inch. In some examples, the BD is between about 0.01 inches and about 1 inch. In some examples, the BD is between about 0.1 inches and about 0.2 inches.

[0053] In some examples, a wall thickness of the housing WT (e.g., the thickness of the housing 12 between the outer surface 30 and the inner surface 32) is determined to maximize heat transfer, minimize weight, and ensure the structural integrity of the housing 12. In one example, the WT is about 0.3 inches. In some examples, the WT is about 0.4 inches. In some examples, the WT is about 0.2 inches. In some examples, the WT is about 0.5 inches. In some examples, the WT is about 0.1 inches. In some examples, the WT is greater than about 0.1 inches. In some examples, the WT is greater than about 0.2 inches. In some examples, the WT is greater than about 0.05 inches. In some examples, the WT is greater, examples, the WT is less than about 0.3 inches. In some examples, the WT is less than about 0.4 inches.In some examples, the WT is less than about 0.5 inches. In some examples, the WT is less than about 1 inch. In some examples, the WT is between about 0.01 inches and about 1 inch. In some examples, the WT is between about 0.2 inches and about 0.4 inches.

[0054] [Fig. 9] is a partial top view of a heat transfer area 22 of the exemplary motor controller assembly 10. In some examples, a boss 36 may include a rounded portion 36a and a tail portion 36b. The rounded portion 36a may be circular, in some examples, and may be defined by a droplet / boss radius DR1 as defined in [Fig. 10A] and 10B. In some examples, the rounded portion 36a may be oriented toward the flow inlet end 26. In some examples, the rounded portion may be oriented toward the flow inlet end 26. In some examples, the tail portion 36b may be oriented toward the flow outlet end 28. In some examples, the tail end 36b is aligned with an end of a fin 34. In some examples, the tail end 36b is aligned with a channel 50.

[0055] [Fig.10A] is a schematic top view of a first embodiment of a drop-shaped boss 36 of a heat transfer area 22 of the exemplary motor controller assembly 10. In some examples, a rounded portion 36b of the boss 36 is defined by a drop / boss radius DR1. In some examples, as noted above, DR1 is determined at least in part based on the BT. In one example, the DR1 is equal to about 0.2 inches. In some examples, the DR1 is equal to about 0.1 inches. In some examples, the DR1 is equal to about 0.3 inches. In some examples, the DR1 is equal to about 0.05 inches. In some examples, the DR1 is equal to about 0.5 inches. In some examples, the DR1 is greater than about 0.1 inches. In some examples, the DR1 is greater than about 0.2 inches. In some examples, the DR1 is greater than about 0.05 inches. In some examples, the DR1 is greater than about 0.01 inches. In some examples, the DR1 is less than about 0.3 inches. In some examples, the DR1 is less than about 0.2 inches. In some examples, the DR1 is less than about 0.5 inches. In some examples, the DR1 is less than about 1 inch. In some examples, the DR1 is between about 0.01 inch and about 1 inch.In some examples, the DR1 is between about 0.1 inches and about 0.3 inches.

[0056] In some examples, the tail portion 36b is defined by a drop / bump angle DA. In some examples, the DA is determined at least in part based on the DR1 and / or the drop / bump length DL, as described below and in [Fig. 11B]-D. In one example, the DA is about 35°. In some examples, the DA is about 30°. In some examples, the DA is about 40°. In some examples, the DA is about 20°. In some examples, the DA is about 50°. In some examples, the DA is about 25°. In some examples, the DA is about 45°. In some examples, the DA is less than about 35°. In some examples, the DA is less than about 30°. In some examples, the DA is less than about 40°. In some examples, the DA is less than about 50°. In some examples, the DA is less than about 45°.In some examples, the DA is greater than about 35°. In some examples, the DA is greater than about 30°. In some examples, the DA is greater than about 40°. In some examples, the DA is greater than about 10°. In some examples, the DA is less than about 25°. In some examples, the DA is between about 35° and about 45°. In some examples, the DA is between about 25° and about 35°. In some examples, the DA is between about 25° and about 55°. In some examples, the DA is between about 30° and about 40°. In some examples, the DA is between about 10° and about 60°.

[0057] In some examples, a drop / bump length DL (e.g., the length between a tip (pointed or rounded tip) of the tail portion 36b and the opposite surface of the rounded portion 36a) is determined to maximize heat transfer, optimize heat transfer fluid flow (also refer to [Fig. 11B]-D), and / or minimize weight. In one example, the DL is equal to about 0.865 inches. In some examples, the DL is equal to about 0.8 inches. In some examples, the DL is equal to about 0.9 inches. In some examples, the DL is equal to about 0.75 inches. In some examples, the DL is equal to about 1 inch. In some examples, the DL is less than about 0.8 inches. In some examples, the DL is less than about 0.9 inches. In some examples, the DL is less than about 1.5 inches. In some examples, the DL is less than about 1 inch. In some examples, the DL is greater than about 0.8 inches. In some examples, the DL is greater than about 0.9 inches. In some examples, the DL is greater than about 0.75 inches. In some examples, the DL is greater than about 0.1 inches. In some examples, the DL is between about 0.1 inches and about 1.5 inches. In some examples, the DL is between about 0.8 inches and about 0.9 inches.In some examples, the DL is between about 0.4 inches and about 1.2 inches.

[0058] [Fig. 10B] is a top schematic view of a second embodiment of a drop-shaped boss 36 of a heat transfer zone 22 of the exemplary motor controller assembly 10. In some examples, the tip of the tail end 36b is rounded. The rounded tip of the tail portion 36b may be defined by a drop / boss tail radius DR2, which may be determined based on manufacturing requirements (e.g., the required path of a manufacturing bit or other tool). In one example, the DR2 is about 0.02 inches. In some examples, the DR2 is about 0.01 inches. In some examples, the DR2 is about 0.03 inches. In some examples, the DR2 is about 0.005 inches. In some examples, the DR2 is about 0.05 inches. In some examples, the DR2 is greater than about 0.01 inch. In some examples, the DR2 is greater than about 0.02 inch.In some examples, the DR2 is greater than about 0.005 inches. In some examples, the DR2 is greater than about 0.001 inches. In some examples, the DR2 is less than about 0.03 inches. In some examples, the DR2 is less than about 0.02 inches. In some examples, the DR2 is less than about 0.05 inches. In some examples, the DR2 is less than about 0.1 inches. In some examples, the DR2 is between about 0.001 inches and about 0.1 inches. In some examples, the DR2 is between about 0.01 inches and about 0.03 inches.

[0059] In such an example where the tip of the tail portion 36b is rounded, the DL may be lower, for a boss 36 of the same DR1, than it would preferably have been if the boss 36 had a pointed tail portion tip 36b.

[0060] [Fig. 1 1A] is an exemplary flow diagram of an exemplary circular boss 58. In such an example, when a flow F1 of heat transfer fluid encounters the circular boss 58, it is deflected around the circular boss 58. When the heat transfer fluid passes the circular boss 58, a weak or stagnant flow zone Al is formed immediately downstream of the circular boss 58, and some of the heat transfer fluid may even flow back (upstream) to the downstream side of the circular boss 58. In the zone Al, the heat transfer is poor / inefficient due to the weak, stagnant and / or recirculating flow of the heat transfer fluid.

[0061] [Fig. 1 1B] is an exemplary flow pattern of an exemplary shortened teardrop boss 60. In such an example, when a flow F2 of heat transfer fluid encounters the shortened teardrop boss 60, it is deflected around the shortened teardrop boss 60. As the heat transfer fluid passes the shortened teardrop boss 60, a zone A2 of weak or stagnant flow may form immediately downstream of the shortened teardrop boss 60, and some of the heat transfer fluid may even flow back (upstream) to the downstream side of the shortened teardrop boss 60. In zone A2, heat transfer is weak or inefficient due to the weak, stagnant, and / or recirculating flow of the heat transfer fluid.However, the area A2 created by the shortened teardrop boss 60 may be smaller than the area A1 created by the circular boss 58 and may result in somewhat improved heat transfer compared to the circular boss 58.

[0062] [Fig. 1 IC] is an exemplary flow pattern of an exemplary elongated teardrop boss 62. In such an example, when a flow F3 of heat transfer fluid encounters the elongated teardrop boss 62, it is deflected around the elongated teardrop boss 62. As the heat transfer fluid passes the elongated teardrop boss 62, no (or minimal) areas of low or stagnant flow may form immediately downstream of the elongated teardrop boss 62. When an elongated teardrop boss 62 is used, heat transfer is improved (compared to a circular boss 58 or a shortened teardrop boss 60, for example) due to the improved flow of the heat transfer fluid.However, if the length of the elongated drop-shaped boss 62 is too long, the flow of heat transfer fluid along the additional length of the elongated sides of the boss 64a and 64b may result in additional friction and less than optimal fluid flow properties. In addition, an elongated drop-shaped boss 62 may have more material, and therefore more weight, than a shorter drop-shaped boss.

[0063] [Fig. 11D] is an exemplary flow diagram of an exemplary drop-shaped boss 66 (e.g., boss 36 of heat transfer area 22 of exemplary motor controller assembly 10). In this example preferred, when a flow F4 of heat transfer fluid encounters the drop-shaped boss 66, it is deflected around the drop-shaped boss 66. As the heat transfer fluid passes the drop-shaped boss 66, no (or minimal) areas of low or stagnant flow may form immediately downstream of the drop-shaped boss 66. When a drop-shaped boss 66 is used, heat transfer is improved (compared to a circular boss 58 or a shortened drop-shaped boss 60, for example) due to the improved flow of the heat transfer fluid. Furthermore, by preventing the sides and length of the drop-shaped boss 66 from becoming too long, the fluid flow properties of the heat transfer fluid along the sides and the weight of the drop-shaped boss 66 can be optimized.

[0064] [Fig. 12] is an exemplary method 120 of cooling one or more heat-generating components (e.g., to cool one or more electrical components 44). In operation 122, a flow path is defined through a heat transfer region on a first surface of a housing. The heat-generating component (in some examples, the heat-generating component is one of a plurality of heat-generating components) is mounted on a second surface of the housing opposite the first surface. The heat transfer region is defined by the first surface, a pair of sidewalls extending from the first surface, and a cover extending over the flow path and connected to the pair of sidewalls.

[0065] The flow path may include a first plurality of channels defined between each of a plurality of parallel fins disposed between the two sidewalls and a second plurality of channels defined around the perimeters of one or more bosses. Each boss may interrupt at least one of the parallel fins. Each boss includes a rounded portion and a tail portion. The rounded portion is oriented toward a flow path inlet of the heat transfer region and the tail portion is oriented toward a flow path outlet of the heat transfer region.

[0066] In operation 124, a driving force is provided to a heat transfer fluid at the flow path inlet. In some examples, the driving force may be provided to the heat transfer fluid by a fan, for example when the heat transfer fluid is a gas. In some examples, the driving force may be provided to the heat transfer fluid by a pump, for example when the heat transfer fluid is a liquid.

[0067] In operation 126, the heat transfer fluid is driven along the flow path toward the flow path outlet. In some examples, heat / thermal energy is removed from the heat generating component by the heat transfer fluid.

[0068] For the purposes of this application, terms such as "upper", "lower", "upwards" and "downwards" are intended to be descriptive with reference to and in relation to the orientation illustrated in the figures for clarity, but examples as practiced and included within the scope of the claims may include examples where the systems and devices are in a different orientation.

[0069] Although particular uses of the technology have been illustrated and discussed above, the disclosed technology may be used in a variety of environments in accordance with numerous examples of the technology. The above discussion is not intended to suggest that the disclosed technology is uniquely suitable for implementation in the environments shown and described above. It should be noted that the various aspects described in the figures are not intended to limit the technology to the particular aspects described. Accordingly, other configurations may be used to implement the technology described herein and / or certain described aspects may be excluded without departing from the methods and systems disclosed herein.

[0070] The present disclosure describes certain aspects of the present technology with reference to the accompanying drawings, in which only some of the possible aspects have been shown. However, other aspects may be embodied in many different forms and should not be construed as being limited to the aspects shown herein. Rather, these aspects have been provided so that this disclosure is complete and exhaustive and fully conveys the scope of the possible aspects to those skilled in the art.

[0071] Similarly, when the operations of a method are disclosed, these operations are described for the purpose of illustrating the present technology and are not intended to limit the disclosure to a particular sequence of operations. For example, the operations may be performed in a different order, two or more operations may be performed simultaneously, additional operations may be performed, and disclosed operations may be excluded without departing from the present disclosure. Furthermore, each operation may be performed through one or more sub-operations. The described processes may be repeated.

[0072] Although specific aspects have been described herein, the scope of the technology is not limited to these specific aspects. Those skilled in the art will recognize other aspects or improvements that are within the scope of the present technology. Therefore, the specific structure, acts, or operations are disclosed for illustrative purposes only. The scope of the technology is defined by the claims following and all their equivalents. Examples of the description may be described according to the following aspects.

[0073] Aspect 1. An enclosure arrangement, comprising: a housing; a heat generating component mounted at a first surface of the housing; and a heat transfer region disposed at a second surface of the housing opposite the heat generating component, the heat transfer region comprising: a plurality of fins disposed at the heat transfer region, the fins extending parallel to each other to define channels therebetween, the channels extending between the inlet and the outlet of the heat transfer region, a first of the fins being interrupted at a boss area disposed at an intermediate location along the first fin, the boss area separating a first of the channels into a first section and a second section;and a boss disposed at the boss region, the boss comprising a rounded portion and a tail portion, the rounded portion facing the first section of the first channel, the tail portion facing the second section of the first channel, the boss having a perimeter defining a flow path between the first section of the first channel and the second section of the first channel.;

[0074] Aspect 2. The enclosure arrangement of aspect 1, wherein the boss region also separates a second of the channels into respective first and second sections, the first fin separating the first and second channels, the rounded portion of the boss facing the first section of the second channel, and the tail portion of the boss facing the second section of the second channel.

[0075] Aspect 3. The enclosure arrangement according to any one of aspects 1 to 2, wherein the boss region is one of a plurality of boss regions, each boss region interrupting at least one respective fin; and wherein the boss is one of a plurality of bosses, each boss being located at a respective boss region.

[0076] Aspect 4. The enclosure arrangement according to any one of aspects 1 to 3, wherein the heat generating component is one of a plurality of heat generating components.

[0077] Aspect 5. The enclosure arrangement according to any one of aspects 1 to 4, wherein the heat generating component comprises an electrical component.

[0078] Aspect 6. The enclosure arrangement according to any one of aspects 1 to 5, wherein: the heat generating component is removably mounted on the first surface, and the boss includes a recess for receiving an attachment of the heat generating component.

[0079] Aspect 7. The enclosure arrangement according to any one of aspects 1 to 6 further comprising a cover extending over the heat transfer region.

[0080] Aspect 8. The enclosure arrangement according to any one of aspects 1 to 7 further comprising a machine connected to the housing and configured to drive a heat transfer fluid along the flow path from the inlet to the outlet of the heat transfer region.

[0081] Aspect 9. The enclosure arrangement according to aspect 8, wherein the heat transfer fluid comprises a gas.

[0082] Aspect 10. The enclosure arrangement according to aspect 8, wherein the heat transfer fluid comprises a liquid.

[0083] Aspect 11. The enclosure arrangement according to any one of aspects 1 to 10, wherein: the rounded portion is defined by a first radius, and the tail portion comprises a rounded tip defined by a second radius.

[0084] Aspect 12. A heat transfer apparatus comprising: a heat transfer region disposed at a first surface of a housing, wherein the heat generating component is mounted on a second surface of the housing opposite the heat transfer region; a plurality of fins disposed at the heat transfer region, the fins extending parallel to each other to define channels therebetween, the channels extending between the inlet and the outlet of the heat transfer region, a first of the fins being interrupted at a boss region disposed at an intermediate location along the first fin, the boss region separating a first of the channels into a first section and a second section;and a boss disposed in the boss region, the boss comprising a rounded portion and a tail portion, the rounded portion facing the first section of the first channel, the tail portion facing the second section of the first channel, the boss comprising a recess for receiving an attachment of the heat generating component, the boss having a perimeter defining a flow path between the first section of the first channel and the second section of the first channel. ;

[0085] Aspect 13. The heat transfer apparatus of aspect 12 further comprising a machine connected to the housing and configured to drive a heat transfer fluid along the flow path from the inlet to the outlet of the heat transfer region.

[0086] Aspect 14. The heat transfer apparatus of aspect 13, wherein the heat transfer fluid comprises a gas.

[0087] Aspect 15. The heat transfer apparatus of aspect 13, wherein the heat transfer fluid comprises a liquid.

[0088] Aspect 16. A method of cooling a heat generating component, the method comprising: defining a flow path through a heat transfer region on a first surface of a housing, wherein: the heat generating component is mounted on a second surface of the housing opposite the first surface, the heat transfer region is defined by the first surface, a pair of sidewalls extending from the first surface, and a cover extending over the flow path and connected to the pair of sidewalls, and the flow path comprises: a first plurality of channels defined between each of a plurality of parallel fins disposed between the pair of sidewalls;and a second plurality of channels defined around perimeters of one or more bosses, wherein each boss interrupts at least one of the parallel fins, and wherein: each boss includes a rounded portion and a tail portion, the rounded portion is oriented toward a flow path inlet of the heat transfer region, and the tail portion is oriented toward a flow path outlet of the heat transfer region; providing a driving force to a heat transfer fluid at the flow path inlet; and driving the heat transfer fluid along the flow path toward the flow path outlet. ;

[0089] Aspect 17. The method of aspect 16, further comprising providing a driving force to a heat transfer fluid via a fan.

[0090] Aspect 18. The method of aspect 16, further comprising providing a driving force to a heat transfer fluid via a pump.

[0091] Aspect 19. The method of any one of aspects 16 to 18, wherein the heat generating component is one of a plurality of heat generating components.

[0092] Aspect 20. The method of any one of aspects 16 to 19, further comprising: mounting the heat generating component on the second surface, comprising inserting a fastener into a recess in each boss.

Claims

Claims

1. An enclosure arrangement comprising: a housing; a heat generating component mounted at a first surface of the housing; and a heat transfer region disposed at a second surface of the housing opposite the heat generating component, the heat transfer region comprising: a plurality of fins disposed at the heat transfer region, the fins extending parallel to each other to define channels therebetween, the channels extending between the inlet and the outlet of the heat transfer region, a first of the fins being interrupted at a boss region disposed at an intermediate location along the first fin, the boss region separating a first of the channels into a first section and a second section;and a boss disposed at the boss region, the boss comprising a rounded portion and a tail portion, the rounded portion facing the first section of the first channel, the tail portion facing the second section of the first channel, the boss having a perimeter defining a flow path between the first section of the first channel and the second section of the first channel.;

2. An enclosure arrangement according to claim 1, wherein the boss region also separates a second of the channels into respective first and second sections, the first fin separating the first and second channels, the rounded portion of the boss facing the first section of the second channel, and the tail portion of the boss facing the second section of the second channel.

3. An enclosure arrangement according to any one of claims 1 to 2, wherein the boss region is one of a plurality of boss regions, each boss region interrupting at least one respective fin; and wherein the boss is one of a plurality of bosses, each boss being located at a respective boss region.

4. An enclosure arrangement according to any one of claims 1 to 3, wherein the heat generating component comprises an electrical component.

5. An enclosure arrangement according to any one of claims 1 to 4, wherein: the heat generating component is removably mounted on the first surface, and the boss comprises a recess for receiving an attachment of the heat generating component.

6. An enclosure arrangement according to any one of claims 1 to 5, further comprising a cover extending over the heat transfer region.

7. An enclosure arrangement according to any one of claims 1 to 6, further comprising a machine connected to the housing and adapted to drive a heat transfer fluid along the flow path from the inlet to the outlet of the heat transfer region.

8. An enclosure arrangement according to any one of claims 1 to 7, wherein: the rounded portion is defined by a first radius, and the tail portion comprises a rounded tip defined by a second radius.

9. A heat transfer apparatus, comprising: a heat transfer region disposed at a first surface of a housing, wherein the heat generating component is mounted on a second surface of the housing opposite the heat transfer region; a plurality of fins disposed at the heat transfer region, the fins extending parallel to each other to define channels therebetween, the channels extending between the inlet and the outlet of the heat transfer region, a first of the fins being interrupted at a boss region disposed at an intermediate location along the first fin, the boss region separating a first of the channels into a first section and a second section;and a boss disposed at the boss region, the boss comprising a rounded portion and a tail portion, the rounded portion facing the first section of the first channel, the; tail portion facing the second section of the first channel, the boss including a recess for receiving an attachment of the heat generating component, the boss having a perimeter defining a flow path between the first section of the first channel and the second section of the first channel.

10. The heat transfer apparatus of claim 9, further comprising a machine connected to the housing and configured to drive a heat transfer fluid along the flow path from the inlet to the outlet of the heat transfer region.

11. A method of cooling a heat generating component, the method comprising: defining a flow path through a heat transfer region on a first surface of a housing, wherein: the heat generating component is mounted on a second surface of the housing opposite the first surface, the heat transfer region is defined by the first surface, a pair of side walls extending from the first surface, and a cover extending over the flow path and connected to the pair of side walls, and the flow path comprises: a first plurality of channels defined between each of a plurality of parallel fins disposed between the pair of side walls;and a second plurality of channels defined around perimeters of one or more bosses, wherein each boss interrupts at least one of the parallel fins, and wherein: each boss includes a rounded portion and a tail portion, the rounded portion is oriented toward a flow path inlet of the heat transfer region, and the tail portion is oriented toward a flow path outlet of the heat transfer region; providing a driving force to a heat transfer fluid at the flow path inlet; and driving the heat transfer fluid along the flow path toward the flow path outlet.;

12. The method of claim 11, further comprising providing a driving force to a heat transfer fluid via a fan.

13. The method of claim 11, further comprising providing a driving force to a heat transfer fluid via a pump.

14. A method according to any one of claims 11 to 13, wherein: the heat generating component is one of a plurality of heat generating components.

15. The method of any one of claims 11 to 14, further comprising: mounting the heat generating component on the second surface, comprising inserting a fastener into a recess in each boss.

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