Electric motor using heat spreader and cartridge type control assembly

Abstract

The motor assembly includes a housing having a motor cavity. A stator is disposed within the housing. A rotor rotates within the stator and within the motor cavity about an axis of rotation. The controller is coupled to the stator having a filter circuit board and a main circuit board interconnected at terminal headers to define a multi-layer circuit board assembly. The circuit board assembly includes an electrical interface and a data interface mounted to at least one of the filter circuit board and the main circuit board.

Description

[Technical field]

[0001] The device relates to the field of fluid pumps, and more particularly to the field of fluid pumps that utilize a heat spreader to remove heat within the device generated by the high amperage currents required to operate the fluid pump, typically in electric vehicles. [Background technology]

[0002] Fluid pumps are used to move fluid materials from a reservoir to a point of use and then back to the reservoir. These fluid pumps can be attached to a serpentine belt or other rotating components in an engine, or can be dedicated electrical assemblies to operate an electric motor. These devices can include fluid flow mechanisms to address thermal issues within the fluid pump. Summary of the Invention

[0003] According to a first aspect of the disclosure, a motor assembly includes a housing having a motor cavity. A stator is disposed within the housing. A rotor rotates within the stator and within the motor cavity about an axis of rotation. A controller is coupled to the stator having a filter circuit board and a main circuit board interconnected at terminal headers to define a multi-layer circuit board assembly. The circuit board assembly includes an electrical interface and a data interface attached to at least one of the filter circuit board and the main circuit board.

[0004] According to another aspect, the motor assembly includes a wound stator overmolded to form a housing having a motor cavity within the stator, a rotor rotates within the motor cavity about an axis of rotation, and a controller includes a filter circuit board and a main circuit board interconnected at terminal headers to define a multi-layer circuit board assembly including electrical surface mount technology electrical sockets for mounting motor terminals in electrical communication with the main circuit board.

[0005] According to another aspect, a motor assembly includes a wound stator overmolded to form a housing with the motor. The rotor rotates within the motor cavity about an axis of rotation. A heat spreader is attached to the housing. The heat spreader includes a heat sink and a hollow shaft extending into the motor cavity defining the axis of rotation. The heat sink removes heat from the circuit board assembly and transfers the heat to a heat exchange medium that circulates through the motor cavity and the hollow shaft.

[0006] These and other aspects, objects and features of the present disclosure will be understood and appreciated by those skilled in the art upon review of the following specification, claims, and accompanying drawings.

[0007] The drawing is as follows. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a perspective view of an embodiment of a fluid pump incorporating an embodiment of a circuit board assembly. [Diagram 2] FIG. 2 is a cross-sectional view of the fluid pump of FIG. 1 taken along line II-II. [Diagram 3] FIG. 2 is a cross-sectional view of the fluid pump of FIG. 1 taken along line III-III. [Figure 4] FIG. 2 is an exploded perspective view of the fluid pump of FIG. 1. [Diagram 5] 2 is another exploded perspective view of the fluid pump of FIG. 1. [Figure 6] FIG. 2 is an enlarged cross-sectional view of the circuit board assembly showing the engagement of electrical and data connections of the circuit board assembly with multiple printed circuit boards; [Figure 7] FIG. 2 is an enlarged cross-sectional view of the circuit board assembly showing the engagement of electrical and data connections with the circuit board assembly. [Figure 8] FIG. 2 is an enlarged perspective view of one embodiment of a circuit board assembly. [Figure 9] FIG. 9 is a perspective view of one embodiment of a controller cartridge including the circuit board assembly of FIG. [Figure 10] 1 is a perspective view of a primary connector having blades and a data connector that engages a circuit board assembly; [Figure 11] FIG. 2 is a cross-sectional view illustrating one embodiment of a heat spreader positioned within a housing and between a motor cavity and a controller cavity. [Figure 12] FIG. 2 is a schematic perspective view of one embodiment of a heat spreader illustrating the movement of heat exchange media from the heat spreader. [Figure 13] FIG. 2 is a plan view of a center pole of a heat spreader positioned within an impeller of a fluid pump. [Figure 14] FIG. 2 is a perspective view of a stator used in a fluid pump. [Figure 15] 1A-1C are perspective views showing the progress of assembly of the rotor and impeller of the fluid pump. [Figure 16] 11A-11C are perspective views showing the progression of assembly of circuit board assemblies to form a controller cartridge. [Figure 17] FIG. 13 is a detailed perspective view showing the engagement of the stator housing and control circuit with the circuit board assembly. [Figure 18] 1 is a cross-sectional view taken along a blade of the connector showing engagement with an upper portion of an electrical terminal of a circuit board assembly; FIG. [Figure 19] 1 is a cross-sectional view taken along a blade of the connector showing engagement with a lower portion of an electrical terminal of a circuit board assembly; FIG. [Figure 20] 13 is a top perspective view showing the installation of a wave spring for preloading the controller cartridge in the controller cavity of the housing, positioned between the controller cartridge and the top cap. FIG. [Figure 21] FIG. 2 is a perspective view of the fluid pump of FIG. 1, with the housing shown in phantom to illustrate the positioning of the internal components of the fluid pump. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Where necessary, detailed embodiments of the present disclosure are disclosed herein; however, it should be understood that the disclosed embodiments are merely exemplary of the present invention, which may be embodied in various and alternative forms. The figures are not necessarily to detailed design, and some schematic diagrams may be exaggerated or minimized to show an overview of the functions. Therefore, specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching those skilled in the art to employ the present invention in various ways.

[0010] For purposes of description herein, the terms "top," "bottom," "right," "left," "back," "front," "vertical," "horizontal," and their derivatives shall refer to the concepts as oriented in FIG. 1. However, it should be understood that the concepts may assume various alternative orientations, unless expressly specified to the contrary. It should also be understood that the specific devices and processes illustrated in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0011] This illustrated embodiment resides primarily in a combination of method steps and apparatus components related to a fluid pump including a heat transfer system for receiving high power current to operate a plurality of electrical contacts and a motor assembly of the fluid pump. Accordingly, the apparatus components and method steps, where applicable, have been represented by conventional numerals in the drawings showing only those specific details relevant to understanding the embodiments of the present disclosure, so as not to obscure the present disclosure with details that will be readily apparent to one of ordinary skill in the art having the benefit of the description herein. Additionally, like numerals in the description and drawings represent like elements.

[0012] The term "and / or," when used in a list of two or more items, means that any one of the listed items can be employed alone, or any combination of two or more of the listed items can be employed. For example, if a composition is described as including components A, B, and / or C, the composition can include only A, only B, only C, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C.

[0013] In this document, relative terms such as first and second, top and bottom, etc. are used only to distinguish one entity or action from another without necessarily requiring or implying any such actual relationship or order between such entities or actions. "Comprises," "comprising," or any other variation is intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent in such process, method, article, or apparatus. An element preceded by "comprises...a" does not, without further constraints, preclude the presence of additional identical elements in a process, method, article, or apparatus that comprises that element.

[0014] As used herein, the term "about" means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller, as appropriate, to reflect tolerances, conversion factors, rounding, measurement errors, and the like, and other factors known to those skilled in the art. When the term "about" is used in describing a value or an endpoint of a range, the disclosure should be understood to include the specific value or endpoint referenced. Regardless of whether a numerical value or endpoint of a range in the specification is described as "about," the numerical value or endpoint of the range is intended to include two embodiments, those modified by "about" and those not modified by "about." Furthermore, it will be understood that each endpoint of a range is significant both in relation to the other endpoint and independently of the other endpoint.

[0015] As used herein, the terms "substantial," "substantially," and variations thereof are intended to note that a described feature is equal or nearly equal to a value or description. For example, a "substantially planar" surface is intended to describe a surface that is planar or nearly planar. Additionally, "substantially" is intended to describe two values ​​that are equal or nearly equal. In some embodiments, "substantially" may describe values ​​that are within about 10% of each other, such as within about 5% of each other or within about 2% of each other.

[0016] As used herein, the terms "the," "a," or "an" mean "at least one" and should not be limited to "only one" unless expressly indicated to the contrary. Thus, for example, reference to "a component" includes embodiments having two or more such components, unless the context clearly indicates otherwise.

[0017] 1-21, reference numeral 10 generally refers to a fluid pump having a fluid inlet 12 and a fluid outlet 14 through which a process fluid 16 travels from a first location to a second location and then returns to the fluid inlet 12 for recirculation through a specific dedicated assembly. It is contemplated that the fluid pump 10 may be installed in any one of a variety of mechanisms and vehicles. Such vehicles may include conventional internal combustion engine vehicles, hybrid vehicles, or electric vehicles. In accordance with various aspects of the device, the fluid pump 10 described herein is typically used in an electric vehicle that provides a high amperage current 18 to the fluid pump 10 for operating various components of the fluid pump 10. The fluid pump 10 includes a motor assembly 20 having a stator 22 with windings 24. The stator 22 and windings 24 are covered or encased in an overmold 48 to form a housing 26 having a motor cavity 28 disposed within a portion of the overmold 48 that surrounds the stator 22. The housing 26 also includes a controller cavity 30 that receives a controller cartridge 32 having a circuit board assembly 34. A rotor 36 is disposed within the motor cavity 28 and in electromagnetic communication with the stator 22. The rotor 36 is rotatably operable about an axis of rotation 38. The rotor 36 includes a drive shaft 40 attached to an impeller 42 for rotating the impeller 42 about the axis of rotation 38. As discussed herein, the impeller 42 is used to move a process fluid 16 between the fluid pump 10 and a dedicated assembly via a fluid inlet 12 and a fluid outlet 14 of the fluid pump 10. Additionally, the action of the rotor 36 and impeller 42 serves to circulate a heat exchange medium 44 through the motor cavity 28 for dissipating heat 46 generated at least within the circuit board assembly 34 .

[0018] 1-21, the fluid pump 10 includes a controller cartridge 32 having a filter circuit board 60 and a main circuit board 62 interconnected by a terminal header 64 to define a multi-layer circuit board assembly 34. The circuit board assembly 34 has a main electrical interface 66 that mounts to the filter circuit board 60. The circuit board assembly 34 also includes at least one data interface that engages at least one of the filter circuit board 60 and the main circuit board 62. In certain embodiments, the data interface may include a single data connector. The data interface may also include a first data interface 68 mounted to the filter circuit board 60 and a second data interface 70 mounted to the main circuit board 62. If desired, power and communications may be transferred between the filter circuit board 60 and the main circuit board 62 using a terminal header 64 that extends between the filter circuit board 60 and the main circuit board 62.

[0019] The heat spreader 80 is attached to the housing 26 and is typically positioned between the motor cavity 28 and the controller cavity 30. The heat spreader 80 includes a shaft 82 and a heat sink 84. The shaft 82, typically in the form of a hollow shaft 82, extends into the motor cavity 28 along the axis of rotation 38. A hollow section 214 of the shaft 82 defines a portion of a flow path 86 for the heat exchange medium 44. The heat sink 84 removes heat 46 from the circuit board assembly 34 and allows the heat 46 to be transferred from the controller cavity 30, through the heat sink 84, to the motor cavity 28 and the heat exchange medium 44 circulating through the hollow section 214 of the shaft 82 of the heat spreader 80.

[0020] 1-11, controller cartridge 32 includes a circuit board assembly 34 disposed within controller cavity 30 of housing 26. Controller cartridge 32 is a pre-assembled cartridge, sometimes typically referred to as a controller pack, that includes a support frame 100. Support frame 100 includes positioning mechanisms 102 and mounting features 104 that serve to position filter circuit board 60 and main circuit board 62 within support frame 100. Filter circuit board 60, sometimes referred to as a pi filter board, incorporates capacitors, inductors, and other larger electrical components typically found in a printed circuit board (PCB).

[0021] 1-11, the filter circuit board 60 includes main electrical terminals 110 and ground terminals 112 of the electrical interface 66 that receive terminal blades 114 of a connector 116, sometimes referred to herein as a main connector 116 or main header. The connector 116 receives external power and also allows for the transfer of data communication between the controller cartridge 32 and an external controller. As discussed herein, the blades 114 of the connector 116 serve to transfer a large amount (high amperage) of electrical current 18 through the connector 116 and into the circuit board assembly 34. This electrical current 18 can be in the range of about 10 amps to about 50 amps and various ranges therebetween. Typically, the blades 114 conduct about 30 amps to about 40 amps from the electrical source to the circuit board assembly 34. This high level of electrical current 18 transferred to the circuit board assembly 34 requires a significant cross-sectional area representing the electrical terminals 110 and the ground terminals 112. As illustrated herein, the electrical terminals 110 and the ground terminals 112 provide an increased contact area and therefore an efficient flow of the high amperage electrical current 18. Accordingly, the terminal blades 114 are bifurcated to engage opposite sides of the filter circuit board 60. The filter circuit board 60 includes a set of upper sockets 118 and a set of lower sockets 120 positioned on opposite sides of the filter circuit board 60. Each of the set of upper sockets 118 and the set of lower sockets 120 receives an upper portion 122 or a lower portion 124, respectively, of each blade 114 of the main connector 116. This increase in surface area between the blades 114 of the connector 116 and the filter circuit board 60 provides a more efficient flow of the electrical current 18 within the circuit board assembly 34.

[0022] In addition to the blades 114 or terminal blades 114, the connector 116 includes separate communication connections, typically two communication connections. The blades 114 and communication connections are secured together with an insulation, typically made of resin, to form the structure of the connector 116. The first data interface 68 includes a first communication connector 130 that engages with a first communication port 132 of the filter circuit board 60. The second data interface 70 includes a second communication connector 134 that engages with a second communication port 136 of the main circuit board 62. As discussed herein, the terminal header 64 allows for the transfer of electrical current 18 and data communication between the filter circuit board 60 and the main circuit board 62. The housing 26 includes an insulation and various terminal blades 114, as well as guide interfaces that guide the first communication connector 130 and the second communication connector 134 into engagement with the filter circuit board 60.

[0023] According to various aspects of the device, the first data interface 68 and the second data interface 70 may include a main data connection and an emergency data connection. Using this configuration of the filter circuit board 60, the main circuit board 62, and various connection terminals for receiving data communications, the connector 116 may engage two separate PCBs of the circuit board assembly 34 within a relatively small space. Additionally, high amperage electrical current 18 may be efficiently delivered between the filter circuit board 60 and the main circuit board 62 through the circuit board assembly 34.

[0024] 1-11 , the main circuit board 62 also includes a plurality of terminal sockets 150 that receive corresponding motor terminals 152 from the stator 22. Typically, the stator 22 includes four motor terminals 152 that engage a corresponding set of terminal sockets 150 disposed in the main circuit board 62. These motor terminals 152 may be dry docked into the terminal sockets 150 and then laser welded to define a secure electrical connection between the motor terminals 152 of the stator 22 and the main circuit board 62 of the circuit board assembly 34. These motor terminals 152 and the corresponding terminal sockets 150 are configured to compensate for at least a portion of the high amperage current 18 that may be delivered to the stator 22 to operate the rotor 36.

[0025] The filter circuit board 60 and the main circuit board 62 are each typically formed using a flame retardant epoxy resin material such as FR4 as a preferred exemplary material. In addition, various circuits are disposed onto the filter circuit board 60 and the main circuit board 62 using SMT (surface mount technology) electrical sockets. These SMT electrical sockets are formed on the surfaces of the filter circuit board 60 and the main circuit board 62. The SMT process used and described herein efficiently positions the circuitry and terminal connections that make up the SMT electrical sockets for positioning the various components of the circuit board assembly 34. After the SMT electrical sockets are disposed on the material of the PCB, the various capacitors, inductors, sockets, terminals, and other components of the PCB can be attached. This attachment can include soldering, laser welding, other attachment methods, or mechanical interfaces. At least in the case of the motor terminals 152, the interconnections created between the motor terminals 152 of the stator 22 and the terminal sockets 150 of the circuit board assembly 34 using the SMT process provide consistent, repeatable, and robust electrical connections. This interconnect provides consistent delivery of power to the stator 22 as well as the transfer of data communications between the stator 22 and the circuit board assembly 34 .

[0026] As discussed herein, the filter circuit board 60 includes an upper socket 118 and a lower socket 120 that receive the bifurcated blades 114 of the connector 116 of the fluid pump 10. Each of these blades 114 includes a contoured section 160 that extends around the material of the filter circuit board 60 and has a central slot 162 adapted to engage the upper socket 118 and the lower socket 120, respectively. As discussed herein, this central slot 162 bifurcates each of the blades 114 to provide an increased surface area of ​​the blades 114 for delivering significant electrical current 18 to and through the circuit board assembly 34.

[0027] During assembly of the controller cartridge 32, the filter circuit board 60 is typically designed to have access points 170 around the perimeter 172 of the filter circuit board 60. These access points 170 can be created by making the filter circuit board 60 smaller than the main circuit board 62. Through this configuration, access is provided around or through the filter circuit board 60 to the terminal sockets 150 that receive the motor terminals 152 when the controller cartridge 32 is disposed within the controller cavity 30 of the housing 26. These access points 170 around the filter circuit board 60 of the circuit board assembly 34 provide access to perform laser welding or other attachment processes to the connection points between the motor terminals 152 and the terminal sockets 150. Gaps 174 are also designed into the support frame 100 to allow this access to perform the laser welding operation. These access points 170 and gaps 174 can also provide for conventional soldering, as well as other similar welding and adhesive attachment processes and methods.

[0028] 2-7 and 12-13, the heat spreader 80 positioned between the motor cavity 28 and the controller cavity 30 serves to transfer heat 46 that has built up in the circuit board assembly 34 into the motor cavity 28. The heat 46 is then dissipated through the heat exchange medium 44 and away from the motor cavity 28 to maintain the controller cavity 30 and the circuit board assembly 34 within a particular temperature range. The heat spreader 80 includes a heat sink 84, typically in the form of a thermally conductive material, such as an aluminum member. The heat sink 84 is attached to the housing 26 adjacent the motor cavity 28 and the controller cavity 30. A shaft 82 of the heat spreader 80 extends from the heat sink 84 into the motor cavity 28. A thermal gap interface material 190 is disposed on the heat sink 84 and engages a portion of the circuit board assembly 34, typically the main circuit board 62, to provide a consistent thermal path by which heat 46 can be transferred to the heat sink 84.

[0029] During operation of the motor assembly 20, the rotor 36 operates the impeller 42 to deliver the process fluid 16 into the fluid inlet 12, through the impeller 42, and to the fluid outlet 14. Operation of the motor assembly 20 generates pressure and suction that provides movement of the process fluid 16 through the impeller 42. A portion of this pressure and suction is utilized within the motor cavity 28 to circulate the heat exchange medium 44 within the area defined between the stator 22 and the rotor 36, and through the hollow section 214 of the shaft 82 of the heat spreader 80. Through this configuration, the heat exchange medium 44 travels around the overmold 48 of the rotor 36 and within the overmolded stator 22, and is directed to the base 212 of the heat sink 84 for further recirculation. Fluid slots 210 are disposed within the base 212 of the heat sink 84 to allow the heat exchange medium 44 to be directed into the hollow section 214 of the shaft 82. This hollow section 214 of the shaft 82 extends the length of the shaft 82 to recirculate the heat exchange medium 44 around and around the rotor 36 and between the rotor 36 and the stator 22 of the motor cavity 28 toward the opposing suction side of the fluid pump 10. It is contemplated that this heat exchange medium 44 may be in the form of any one or more of a variety of heat exchange materials, such as glycol, water, an oil-based material, or other similar heat exchange medium 44. Typically, the heat exchange medium 44 is in liquid form, but the heat exchange medium 44 may also be in gas form or a phase change material that may be in either liquid or gas form or both.

[0030] 2-7 and 12-13, positioning the heat sink 84 of the heat spreader 80 provides efficient transfer of heat 46 from the circuit board assembly 34 and controller cavity 30 to the heat exchange medium 44 circulating through the motor cavity 28. This is done to maintain the circuit board assembly 34 and controller cavity 30 within a consistent temperature range, typically less than about 160° C., more typically less than about 150° C. In a particular embodiment of the device, the heat exchange medium 44 is glycol, which can have a maximum temperature of about 110° C. This temperature gradient provides consistent heat exchange between the circuit board assembly 34, the thermal gap interface material 190, the heat sink 84 of the heat spreader 80, and the heat exchange medium 44. This heat exchange medium 44 typically circulates only through the motor cavity 28, and the transferred heat 46 is dissipated as the heat exchange medium 44 circulates through the motor cavity 28.

[0031] In certain embodiments of the device, it is contemplated that the heat exchange medium 44 may generally be delivered to an external location to provide an alternative mechanism for dissipating heat 46 from the controller cavity 30 and fluid pump 10.

[0032] Studies have shown through thermal modeling that positioning the heat sink 84 and shaft 82 of the heat spreader 80 relative to the circuit board assembly 34, generally as illustrated in Figures 2-13, reduces the temperature of the circuit board assembly 34 by about 20°C to about 40°C. This consistent reduction in temperature provides for the use of FR4 material within the PCB of the circuit board assembly 34. This configuration of the device provides for the use of high amperage current within the circuit board assembly 34, while also providing cost-efficient use of FR4 material to manufacture the PCB of the circuit board assembly 34. The heat exchange medium 44 efficiently transfers the heat 46 away from the circuit board assembly 34 to maintain a consistent temperature within the controller cavity 30.

[0033] 2-7 and 12-13, the shaft 82 of the heat spreader 80 typically extends through the rotor 36 to provide a rotational interface that allows the rotor 36 and the drive shaft 40 to move relative to the axis of rotation 38 of the fluid pump 10. Additionally, the shaft 82 includes a hollow section 214 that delivers the heat exchange medium 44 between the pressure side of the motor cavity 28 of the fluid pump 10 and the suction side of the motor cavity 28 of the fluid pump 10. The direction of the heat exchange medium 44 can be varied depending on the particular design of the fluid pump 10 and the motor cavity 28. Thus, the heat exchange medium 44 can be moved from the impeller side of the motor cavity 28, through the shaft 82, and then out of the fluid slots 210 defined in the base 212 of the heat spreader 80. The heat exchange medium 44 can also be moved in the opposite direction depending on the design of the fluid pump 10.

[0034] According to various aspects of the device, assembly of the fluid pump 10, as described herein and illustrated at least in FIGS. 1-21, provides an efficient and repeatable manufacturing process. The manufacturing process involves separate manufacture of the individual components that are assembled to form the fluid pump 10. By way of example and not limitation, the controller cartridge 32 may be manufactured at one location while the housing 26 and motor components of the fluid pump 10 may be manufactured at another location. The impeller 42 and fluid end cap 254 may also be manufactured at another location where these components are assembled in an efficient and convenient manner. To assist in this assembly, various feedback mechanisms in the form of positioning mechanisms 102 and mounting features 104 of the housing 26 and support frame 100 provide indications to the assembler that the components are assembled in the proper orientation and sequence.

[0035] By way of example and not limitation, the motor terminals 152 are not symmetrically positioned about the axis of rotation 38 of the stator 22. Rather, they are positioned at a particular angle such that attachment of these motor terminals 152 to the terminal sockets 150 of the circuit board assembly 34 can only be accomplished in a single rotational orientation of the circuit board assembly 34 relative to the housing 26. The attachment of the circuit board assembly 34 to the housing 26 provides visual feedback, and in certain cases, auditory and tactile feedback, regarding the proper installation of these components. Additionally, during manufacture of the controller cartridge 32, various interface features within the support frame 100 provide for precise positioning of the filter circuit board 60 and the main circuit board 62 within the support frame 100. These components can be attached together once positioned within the support frame 100 to provide a final configuration of the controller cartridge 32 that can be conveniently installed within the controller cavity 30 of the housing 26.

[0036] 2-5 and 14-15, during assembly of the motor assembly 20, the stator 22 is formed from a series of stacked or spirally wound laminations. These laminations may form the entire stator 22 or may form sections of the stator 22 that are attached together to form the core and teeth 230 of the stator 22. After forming the wound stator 22, the windings 24 are disposed about the teeth 230 of the stator 22 and the rotor magnets 232 are positioned within a rotor frame 234 to form the structure of the rotor 36. The rotor frame 234 may be made of the stacked laminations that form pockets that receive the rotor magnets 232. Each of these pump components may be covered or encased in an overmold 48 to form the housing 26 and the motor cavity 28, as well as the rotor 36 having an overmold 48 that may be positioned within the motor cavity 28. An impeller 42 may then be attached to the rotor 36 such that movement of the rotor 36 within the stator 22 causes rotation of the impeller 42 to move the process fluid 16 from the fluid inlet 12 to the fluid outlet 14 of the fluid pump 10.

[0037] As illustrated in Figures 2-5 and 17-21, the overmold 48 of the housing 26 includes various positioning features and attachment mechanisms integrally formed into the material of the overmold 48 surrounding the stator 22. The impeller end 250 of the housing 26 includes a channel 252 that defines a portion of the fluid path between the fluid inlet 12 and the fluid outlet 14, as well as a connection point between the motor terminal 152 and the terminal socket 150 of the circuit board assembly 34. Through this configuration, the correct positioning orientation, or volute, of the fluid end cap 254 with the fluid inlet 12 and the fluid outlet 14 can be ensured through positive feedback in the form of visual, auditory, and tactile cues provided to the assembler. Various seals and gaskets are also positioned between the controller cavity 30 and the motor cavity 28 to ensure that the heat exchange medium 44 remains separated from the controller cavity 30. Additionally, in certain embodiments of the device, the portion of the motor cavity 28 that houses the impeller 42 may be sealed from the remainder of the motor cavity 28 that houses the rotor 36. This sealed configuration may be used to ensure that the heat exchange medium 44 surrounding the rotor 36 and moving through the heat spreader 80 remains separate from the process fluid 16 moved by the impeller 42 through the fluid end cap 254. Thus, the heat exchange medium 44 is contained within the motor cavity 28 to provide a heat exchange function for carrying excess heat 46 away from the circuit board assembly 34.

[0038] 2-5, 8-10, and 16-20, during assembly of the controller cartridge 32, as discussed herein, the filter circuit board 60 and the main circuit board 62 are interconnected via a terminal header 64. The terminal header 64 extends between the filter circuit board 60 and the main circuit board 62. The terminal header 64 may be positioned in a straight line path between the filter circuit board 60 and the main circuit board 62, or may move in a more angled path to provide efficient flow of data connections and current 18 between the filter circuit board 60 and the main circuit board 62. At least one insulator 270 may be positioned around the terminal header 64 to minimize electrical and electromagnetic interactions between the electric fields that may be generated by the large amount of current 18 delivered through the circuit board assembly 34. As discussed herein, the filter circuit board 60 is configured to be a different size and shape than the main circuit board 62 to allow access to the main circuit board 62 for laser welding and other connection operations for the manufacture of the controller cartridge 32. The controller cartridge 32 is then placed into the controller cavity 30 of the housing 26 and engaged to the motor terminals 152 via the terminal sockets 150 to the main circuit board 62 .

[0039] 4-5 and 16-21, the controller cartridge 32 includes a circumferential channel 280 that receives a wave spring 282 that is mounted to the end of the controller cartridge 32. The wave spring 282 engages a top cap 284 and serves to preload the controller cartridge 32 and position it relative to the connector 116 and connector opening 286. Once positioned within the controller cavity 30, the connector 116 having a pair of blades 114 and a pair of data connections can be mounted and attached to various contacts and terminals within the filter circuit board 60 and main circuit board 62. The wave spring 282 secures the controller cartridge 32 relative to the various positioning features 102 within the controller cavity 30 of the housing 26 to ensure that the filter circuit board 60 and main circuit board 62 are positioned relative to the connector opening 286. Once the controller cartridge 32 is aligned with the connector opening 286, the various connectors 116 can be installed through the connector opening 286 to engage the filter circuit board 60 and the main circuit board 62. An O-ring seal 272 is also positioned on the edge of the housing 26 to seal against the top cap 284 to ensure that fluid does not seep into the controller cavity 30.

[0040] The heat exchange medium 44 contained within the motor housing 26 may be used to extract heat 46 from the controller cavity 30 and from the fluid pump 10 as a whole. Extracting heat 46 from the fluid pump 10 may allow a wider range of materials to be used within the fluid pump 10 that may have a higher tolerance to the temperature ranges described herein. The wider range of available materials that may be used within the fluid pump 10 may include more readily available or more cost effective materials. By way of example and not limitation, the material of the PCB of the circuit board assembly 34 may be made of FR4 material. Additionally, the housing 26 may be made of PPS (polyphenylene sulfide). Other polymers may be utilized within the fluid pump 10 as the temperature within the components of the fluid pump 10 is reduced as a result of the heat exchange medium 44 moving through the motor cavity 28.

[0041] As discussed herein, the fluid pump 10 of the present application operates using a very high current 18 with high amperage. To compensate for this high current 18 and high amperage, a number of terminals are included within the filter circuit board 60 for receiving this current 18 from the connector 116 and delivering this current to the main circuit board 62 and then to the various components of the motor assembly 20 and the stator 22 for operating the fluid pump 10. Data connections are communicated to each of the filter circuit board 60 and the main circuit board 62, thereby allowing data to be delivered directly to the capacitors and inductors of the filter circuit board 60 and to terminal sockets 150 disposed within the main circuit board 62.

[0042] 4-5 and 16-21, installation of the top cap 284 engages the wave spring 282 to preload the controller cartridge 32 so that it is biased against the retaining components defined within the controller housing 26. The top cap 284 is then crimped to position the electrical components of the circuit board assembly 34 in the proper axial position to receive the data connections of the blades 114 and connector 116. These upper and lower sockets 118 and 120 may be in the form of molded headers that are electrically connected to form the upper and lower sockets 118 and 120, mounted to the filter circuit board 60 via SMT electrical sockets. These molded headers may be sealingly engaged to the housing 26 and within the controller cavity 30. The controller cartridge 32 includes a support frame 100, typically made of a resin material, that supports the filter circuit board 60 and the main circuit board 62 within the controller cartridge 32 and within the controller cavity 30 of the housing 26. As discussed herein, the support frame 100 includes features for securing large-capacitors and conductors for robustness against test and operational vibrations to which the fluid pump 10 may be subjected during use. The support frame 100 also includes a pocket in the form of a circumferential channel 280 for receiving a wave spring 282 that applies a preload to the controller cartridge 32. As discussed herein, this pocket receives the wave spring 282 that engages a top cap 284 to apply a preload to the controller cartridge 32 within the controller housing 26.

[0043] 1-21, the main circuit board 62 of the motor assembly 20 receives the motor terminals 152 that extend from the stator 22 through portions of the housing 26 and into the controller cavity 30. At the same time, the electrical terminals 110 of the filter circuit board 60 receive electrical current 18 from the blades 114 of the connector 116 through the terminal header 64 and upper and lower sockets 118, 120 defined on either side of the filter circuit board 60. The various terminals may be silver or gold plated to prevent corrosion. Typically, the data connections are also plated in this manner to prevent corrosion. In certain embodiments of the device, connections that receive larger electrical currents 18 may not need to be plated in this manner since the larger electrical currents 18 flow through the connections to keep the connections free of corrosion.

[0044] As illustrated in Figures 1-21, the fluid pump 10 includes an overmold 48 that extends around the windings 24 of the stator 22, which may be made from a resin such as PPS. This is used to form the motor cavity 28 that receives the rotor 36 for operating the fluid pump 10. An isolator component in the form of a heat sink 84 of the heat spreader 80 is made from a thermally conductive material and is typically in the form of an aluminum member that may be bonded, welded, or otherwise connected to the housing 26 or to a base 212 for the heat spreader 80. This heat sink 84 is positioned between the motor cavity 28 and the controller cavity 30 to create a barrier between the two cavities in the radial direction at a seal interface between the overmold 48 of the stator 22 and the isolator component for the heat sink 84. The heat sink 84 creates a thermal path between the dry controller cavity 30 and the wet motor cavity 28 that has a heat exchange medium 44 circulating therethrough. The heat exchange medium 44 is pumped through the motor cavity 28 by use of at least a portion of the pressure and suction generated during operation of the impeller 42 of the fluid pump 10. The shaft 82 of the heat spreader 80 is also utilized to provide circulation of the heat exchange medium 44 through the motor cavity 28.

[0045] The use of the various components of the motor assembly 20, including at least the circuit board assembly 34 and the heat spreader 80, allows the high current 18 to be delivered to the circuit board assembly 34 of the fluid pump 10 without raising the temperature of the controller cavity 30 beyond the failure state of many materials. Thus, a wider range of less heat resistant materials may generally be selected and utilized within the circuit board assembly 34 and the fluid pump 10. Additionally, the use of the heat spreader 80 provides an efficient mechanism for the transfer of heat 46 from the circuit board assembly 34 into the heat exchange medium 44 for dissipation away from the fluid pump 10. Also, the manufacture of separate components in the form of the housing 26, controller cartridge 32, and heat spreader 80 can be manufactured separately and assembled at a specific location by efficient manufacturing processes. The use of this configuration provides a robust mechanical and electrical system for the fluid pump 10 that can be utilized in demanding high current settings.

[0046] It should also be understood that changes and modifications can be made to the structure described above without departing from the concepts of the present disclosure, and further that such concepts are intended to be covered by the following claims unless those claims expressly state otherwise by their language.

Claims

1. 1. A motor assembly comprising: a housing having a motor cavity; a stator disposed within the housing; a rotor that rotates within the stator and within the motor cavity about a rotation axis; a controller coupled to the stator having a filter circuit board and a main circuit board interconnected at terminal headers to define a multi-layer circuit board assembly, the circuit board assembly having an electrical interface and a data interface mounted to at least one of the filter circuit board and the main circuit board.

2. 2. The motor assembly of claim 1 further comprising a heat spreader attached to the housing, the heat spreader having a heat sink and a shaft extending into the motor cavity along the axis of rotation.

3. The motor assembly of claim 2 , wherein the heat sink removes heat from the circuit board assembly and transfers the heat to a heat exchange medium circulating through the motor cavity.

4. The motor assembly of claim 3 , wherein the shaft of the heat spreader is a hollow shaft through which the heat exchange medium is delivered from the circuit board assembly through the motor cavity.

5. The motor assembly of claim 3 , wherein the controller is positioned in a controller cavity adjacent the motor cavity.

6. The motor assembly of claim 5 , wherein the heat sink is an aluminum member disposed adjacent the motor cavity and the controller cavity.

7. The motor assembly of claim 3 , wherein the heat exchange medium is glycol.

8. The motor assembly of claim 3 further comprising a thermal gap interface material disposed between said heat sink and said main circuit board.

9. 4. The motor assembly of claim 3, wherein the shaft of the heat spreader extends through the rotor along the axis of rotation of the rotor, and a drive shaft of the rotor is disposed around the shaft of the heat spreader.

10. 6. The motor assembly of claim 5, wherein the heat spreader includes a base from which the shaft extends, the base including a fluid slot through which the heat exchange medium passes between the controller cavity and the shaft.

11. 11. The motor assembly of claim 1, wherein the multi-layer circuit board assembly is incorporated into a pre-assembled cartridge, the multi-layer circuit board assembly including an electrical surface mount technology (SMT) electrical socket.

12. 12. The motor assembly of claim 11, wherein the SMT electrical socket receives motor terminals of the stator, the SMT electrical socket placing the motor terminals in electrical communication with the main circuit board.

13. The motor assembly of any preceding claim, wherein the main circuit board and the filter circuit board are interconnected at the terminal header to define the multi-layer circuit board assembly.

14. 1. A motor assembly comprising: a wound stator overmolded to form a housing having a motor cavity within the stator; a rotor rotating within the motor cavity about a rotation axis; 1. A motor assembly comprising: a controller including a filter circuit board and a main circuit board interconnected at terminal headers to define a multi-layer circuit board assembly including electrical surface mount technology electrical sockets for mounting motor terminals in electrical communication with the main circuit board.

15. 15. The motor assembly of claim 14, wherein the terminal header includes at least one insulator to limit electromagnetic communication between the filter circuit board and the main circuit board in an area external to the terminal header, and the current delivered through the multilayer circuit board assembly is between about 10 amps and about 50 amps.

16. 16. The motor assembly of claim 15, wherein the controller connector includes electrical terminals that engage upper sockets that receive upper portions of the connector blades and lower sockets that receive lower portions of the connector blades.

17. 17. The motor assembly of claim 16, wherein the connector includes a first data interface that mates with a first communication port of the filter circuit board, and the connector includes a second data interface that mates with a second communication port of the main circuit board.

18. A motor assembly as claimed in any one of claims 14 to 17, wherein the multi-layer circuit board assembly is a pre-assembled cartridge attached to the housing and the wound stator.

19. 1. A motor assembly comprising: a wound stator overmolded to form a housing having the motor; A rotor that rotates within the motor cavity about an axis of rotation; a heat spreader attached to the housing, the heat spreader having a heat sink and a hollow shaft extending into the motor cavity defining the axis of rotation, the heat sink removing heat from a circuit board assembly and transferring the heat to a heat exchange medium circulating through the motor cavity and the hollow shaft.

20. 20. The motor assembly of claim 19, further comprising: a controller coupled to the stator having a filter circuit board and a main circuit board interconnected at terminal headers to define the circuit board assembly, the circuit board assembly having an electrical interface and at least one data interface mounted to at least one of the filter circuit board and the main circuit board.

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