Systems and methods for high voltage isolation with thermal conductivity - Patents.com

Abstract

The system includes a first slice (101) and a second slice (102, 103) coupled to each other. Each slice includes a housing (110) formed of an electrically insulating material, a ceramic plate (130) disposed at each end of the housing, and an end plate (135) disposed on each of the ceramic plates. Each end plate is formed of a thermally conductive material. The system also includes a backplane assembly (120) coupled to the first slice and the second slice.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to power and thermal management systems. More specifically, the present disclosure relates to a system and method for high voltage isolation with thermal conductivity. [Background technology]

[0002] To achieve heat dissipation and high voltage isolation, oil-filled containers or dry insulating tubes have often been used. Oil-filled containers achieve both heat dissipation and high voltage isolation. However, such containers are messy, costly, difficult to rework, and environmentally unfriendly. Insulating tubes achieve only high voltage isolation but provide little or no heat transfer. Summary of the Invention

[0003] The present disclosure provides systems and methods for high voltage isolation with thermal conductivity.

[0004] In a first embodiment, the system includes a first slice and a second slice coupled to each other. Each slice includes a housing formed of an electrically insulating material, a ceramic plate disposed at each end of the housing, and an end plate disposed on each of the ceramic plates. Each end plate is formed of a thermally conductive material. The system also includes a backplane assembly coupled to the first slice and the second slice.

[0005] In a second embodiment, a system includes a hotel power slice and a plurality of accessory slices coupled together. Each slice includes a housing formed of an electrically insulating material, a ceramic plate disposed at each end of the housing, and an end plate disposed on each of the ceramic plates. Each end plate is formed of a thermally conductive material. The system also includes a backplane assembly coupled to the hotel power slice and the plurality of accessory slices.

[0006] In a third embodiment, the method includes providing a first slice and a second slice. Each slice includes a housing formed of an electrically insulating material, a ceramic plate disposed at each end of the housing, and an end plate disposed on each of the ceramic plates. Each end plate is formed of a thermally conductive material. The method also includes bonding the slices together. The method further includes attaching a backplane assembly to the first slice and the second slice.

[0007] Other technical features may be readily apparent to those skilled in the art from the following drawings, descriptions and claims. [Brief description of the drawings]

[0008] For a more complete understanding of the present disclosure, reference is made to the following descriptions taken in conjunction with the accompanying drawings.

[0009] [Figure 1] FIG. 1 illustrates an exemplary thermally conductive, electrically insulated (TCEI) system according to the present disclosure. [Diagram 2] FIG. 1 illustrates an exemplary TCEI system according to the present disclosure. [Diagram 3] FIG. 1 illustrates an exemplary TCEI system according to the present disclosure.

[0010] [Figure 4] FIG. 4 illustrates further details of the example reconfigurable optical add drop multiplexer (ROADM) and hotel power slice of FIGS. 1-3 in accordance with the present disclosure. [Diagram 5] FIG. 4 illustrates further details of the example reconfigurable ROADM and hotel power slice of FIGS. 1-3 in accordance with the present disclosure. [Figure 6]FIG. 4 illustrates further details of the example reconfigurable ROADM and hotel power slice of FIGS. 1-3 in accordance with the present disclosure.

[0011] [Figure 7] 4 illustrates further details of the example accessory slice of FIGS. 1-3 in accordance with the present disclosure. FIG. [Figure 8] 4 illustrates further details of the example accessory slice of FIGS. 1-3 in accordance with the present disclosure. FIG. [Figure 9] 4 illustrates further details of the example accessory slice of FIGS. 1-3 in accordance with the present disclosure. FIG.

[0012] [Figure 10] FIG. 4 illustrates an example electrical boundary for each of the slices of FIGS. 1-3 in accordance with the present disclosure.

[0013] [Figure 11] FIG. 4 illustrates further details of an exemplary one of the slices of FIGS. 1-3, in accordance with the present disclosure.

[0014] [Figure 12] FIG. 1 illustrates an exemplary method for assembling a TCEI system according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] 1 through 12 described below and the various embodiments used to illustrate the principles of the present disclosure in this patent document are for illustrative purposes only and should not be construed as limiting the scope of the present disclosure in any way. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any type of suitably arranged device or system.

[0016] For the sake of brevity and clarity, some features and components are not necessarily explicitly shown in every drawing, including those shown in relation to other drawings. It will be understood that all features shown in the drawings may be employed in any of the embodiments described. The omission of a feature or component from a particular drawing is for the sake of brevity and clarity and is not meant to imply that the feature or component cannot be employed in the embodiment described in relation to that drawing. It will be understood that embodiments of the present disclosure may include any one, two or more, or all of the features described herein. Also, embodiments of the present disclosure may include other features in addition to or in the alternative that are not enumerated herein.

[0017] As discussed above, both oil-filled containers or dry insulating tubes have often been used to achieve both heat dissipation and high voltage isolation. Oil-filled containers achieve both heat dissipation and high voltage isolation. However, such containers are messy, costly, difficult to rework, and environmentally unfriendly. Insulating tubes achieve only high voltage isolation but provide little or no heat transfer.

[0018] The present disclosure provides for electrically isolating electronic equipment assemblies or other heat sources in a closed environment (such as a power feed branching unit) while thermally conducting heat (thermal energy) away from the electronic equipment assemblies or other heat sources. The disclosed systems and methods are cost-effective, easily producible, and easily reworkable in the event of repair or maintenance. The disclosed systems and methods provide a solution for thermal and high voltage management without the use of oil in a closed vessel. In some embodiments, the disclosed systems and methods can be used to house telecommunications equipment in a pressure vessel for subsea applications, although any other suitable applications are within the scope of the present disclosure.

[0019] Figures 1-3 illustrate an exemplary thermally conductive electrically insulating (TCEI) system 100 in accordance with the present disclosure. In particular, Figure 1 illustrates a top isometric view of the TCEI system 100, Figure 2 illustrates a bottom isometric view of the TCEI system 100, and Figure 3 illustrates a partially exploded view of the TCEI system 100. In some embodiments, the TCEI system 100 is configured to be inserted inside a pressure vessel, which may be submerged in a subsea or other environment.

[0020] As shown in FIGS. 1-3, the TCEI system 100 includes a reconfigurable optical add-drop multiplexer (ROADM) and hotel power slice 101 and multiple accessory slices 102-103. Although the TCEI system 100 is shown having two accessory slices 102-103, this is by way of example only and other embodiments may include other numbers of accessory slices 102-103. Each end of the TCEI system 100 is capped with an end plate 115. In some embodiments, each end plate 115 is formed of aluminum, such as 6061-T6 aluminum alloy, although other suitable materials are possible and within the scope of the present disclosure. In some embodiments, each end plate 115 includes one or more fastening or locking mechanisms for attaching the end plate 115 to a corresponding slice 101, 103.

[0021] The ROADM and hotel power slice 101 is configured to house one or more ROADMs and one or more hotel power components for operation of the TCEI system 100. In some embodiments, the ROADM and hotel power slice 101 may house one or more processors, circuit card assemblies (CCAs), hotel power sources, optical network components, other electronic components, other heat sources, or any combination thereof. One, some, or all of these components may operate at high voltage or other potentials that are different from seawater ground or other external ground, and therefore need to be electrically isolated from the external environment. Also, one, some, or all of these components may generate thermal energy that needs to be dissipated from the interior of the ROADM and hotel power slice 101 to prevent overheating. Although the embodiments described herein include the ROADM and hotel power components located in one slice 101, this is merely an example. In other embodiments, the ROADM and hotel power components may be housed in separate slices.

[0022] Each accessory slice 102-103 is configured to house one or more electronic components or other heat sources that receive power from the accessory slice 102-103 itself or from a power source located in the ROADM and hotel power slice 101. In some embodiments, each accessory slice 102-103 is configured as an approximately 1 kW slice, although other power levels are possible and within the scope of this disclosure. As with the ROADM and hotel power slice 101, one, some, or all of the electronic components located in each accessory slice 102-103 may operate at a high voltage or other potential different from seawater ground or other external ground, and therefore need to be electrically isolated from the external environment. Also, one, some, or all of the electronic components located in each accessory slice 102-103 may generate thermal energy that needs to be dissipated from the interior of the accessory slice 102-103 to prevent overheating.

[0023] Each of the slices 101-103 can be assembled and sealed independently. Each of the slices 101-103 includes an electrically insulating housing 110. In some embodiments, the housing 110 is formed of nylon, although other electrically insulating materials are possible and within the scope of the present disclosure. At the ends of each of the slices 101-103, a ceramic plate 130 and an end plate 135 are disposed. Each ceramic plate 130 provides a thermal path between one or more heat generating components disposed with the slice 101-103 and the associated end plate 135. Although each ceramic plate 130 is a good conductor of thermal energy, each ceramic plate 130 is electrically insulated to electrically isolate the internal components from the external environment. In some embodiments, each ceramic plate 130 is formed of boron nitride or aluminum nitride, although other suitable materials are possible and within the scope of the present disclosure. Each end plate 135 provides a thermal path between the associated ceramic plate 130 and the pressure vessel. In some embodiments, each end plate 135 is formed from aluminum, such as 6061-T6 aluminum alloy, although other suitable materials are possible and within the scope of the present disclosure.

[0024] In this example, the bottom side of the TCEI system 100 includes a backplane assembly 120. The backplane assembly 120 is coupled to each of the slices 101-103 to create a hermetic seal between the backplane assembly 120 and each of the slices 101-103. The backplane assembly 120 is formed of an electrically insulating material (such as nylon) and includes a number of high voltage conductors and fiber feedthroughs 125 for passing cables, wires, or other connectors between each of the slices 101-103 and the exterior portion of the TCEI system 100. The cables, wires, or connectors provide power, data transfer, etc. to or from one or more components located within each of the slices 101-103.

[0025] Adjacent slices 101-103 are aligned such that the end plates 135 of adjacent slices 101-103 are also aligned, as shown in FIG. 1. Adjacent slices 101-103 are joined together, such as by using a number of slice joining plates 140 and fasteners 145. Of course, the slice joining plates 140 and fasteners 145 shown in FIGS. 1-3 are merely examples, and other joining mechanisms are possible and within the scope of this disclosure. The backplane assembly 120 is attached to adjacent slices 101-103, as shown in FIGS. 1 and 2, to form a substantially cylindrical overall shape of the TCEI system 100. The substantially cylindrical shape of the TCEI 100 allows for easy loading of the TCEI system 100 into a pressure vessel.

[0026] Figures 4-6 show further details of the exemplary ROADM and hotel power slice 101 of Figures 1-3 in accordance with the present disclosure. In particular, Figure 4 shows an exploded view of the ROADM and hotel power slice 101, Figure 5 shows a cross-sectional view of the ROADM and hotel power slice 101, and Figure 6 shows an isometric view of the ROADM and hotel power slice 101 from an opposite angle to that of Figure 4. As shown in Figures 4-6, the ROADM and hotel power slice 101 includes a ceramic plate 130 and an end plate 135 disposed at each end. Each ceramic plate 130 serves as an electrical insulation layer as discussed above.

[0027] One or more heat generating components 405 are disposed within the cavity 410 of the ROADM and hotel power slice 101. During operation, the heat generating components 405 may generate thermal energy that needs to be dissipated to avoid overheating of the heat generating components 405. As discussed above, the heat generating components 405 may include one or more electrical components that operate at high voltages. For example, the heat generating components 405 may operate at approximately 10-15 kV relative to seawater ground or other external ground. The structure of the ROADM and hotel power slice 101 allows the thermal energy to be transferred out of the cavity 410 while providing an electrically isolated environment for the high voltage heat generating components 405.

[0028] Surrounding the cavity 410 is an internal heat sink 420. The internal heat sink 420 absorbs thermal energy generated by the heat-generating component 405. The thermal energy is then transferred from the internal heat sink to the ceramic plate 130. In some embodiments, the internal heat sink 420 is formed of aluminum, such as 6061-T6 aluminum alloy, although other suitable materials are possible and within the scope of the present disclosure. As generally indicated by the arrows in FIG. 4, the thermal path of the thermal energy is from the heat-generating component 405 to the internal heat sink 420, then to the ceramic plate 130, to the end plate 135, and then to the surrounding pressure vessel for dissipation of the thermal energy to the external environment.

[0029] Seals 415 formed around the circumferential edges of the ROADM and hotel power slices 101 ensure that the cavity 410 is sealed and electrically isolated from the outside environment. In some embodiments, the seals 415 are O-rings formed of a synthetic rubber such as Nitrile, although other suitable materials are possible and within the scope of this disclosure.

[0030] The ROADM and hotel power slice 101 exhibits excellent thermal conductivity (e.g., about 78-180 W / mK) and excellent electrical insulation (e.g., greater than about 15 kV / mm). The design and components of the accessory slices 102-103 may be similar to those of the ROADM and hotel power slice 101, as discussed in connection with Figures 7-9.

[0031] 7-9 show further details of the exemplary accessory slices 102-103 of FIGS. 1-3 according to the present disclosure. In particular, FIG. 7 shows a cross-sectional view of each accessory slice 102-103, FIG. 8 shows a front isometric view of each accessory slice 102-103, and FIG. 9 shows a rear isometric view of each accessory slice 102-103. As shown in FIGS. 7-9, each accessory slice 102-103 includes multiple components that may be the same or similar to corresponding components of the ROADM and hotel power slice 101. For example, each accessory slice 102-103 includes a cavity 410 that houses one or more heat-generating components 405. Around the periphery of the cavity 410 is an internal heat sink 420 that is coupled to the ceramic plate 130 and the end plate 135. The internal heat sink 420 absorbs thermal energy generated by the heat-generating components 405. The thermal energy is transferred to the ceramic plate 130, then to the end plate 135 and to the surrounding pressure vessel for dissipation of the thermal energy to the outside environment.

[0032] FIG. 10 illustrates an exemplary electrical boundary of each of the slices 101-103 of FIGS. 1-3 according to the present disclosure. As illustrated in FIG. 10, a cross-sectional view of one of the slices 101-103 is shown. Line 1001 generally indicates an area of ​​internal potential. Inside the line 1001, the potential of one or more components, such as the heat-generating component 405, may be, by way of example, about 10-15 kV with respect to seawater ground or other external ground. Line 1002 generally indicates an area of ​​external potential, such as seawater ground or other external ground. Line 1003 generally indicates an electrical isolation region between the internal potential and the external potential. In the slices 101-103, the electrical isolation region is formed by the housing 110, the backplane assembly 120, and the ceramic plate 130.

[0033] FIG. 11 illustrates further details of an exemplary one of the slices 101-103 of FIGS. 1-3 according to the present disclosure. As shown in FIG. 11, the slices 101-103 include an inset region 1105 that is configured to receive a portion of the backplane assembly 120. Additionally, charging ports 1110 on the surfaces of the slices 101-103 allow access to the interior portions of the slices 101-103 to backfill the interior portions with one or more gases or liquids or to evacuate the interior portions to create a vacuum or partial vacuum. A cover over the charging ports 1110 can be formed of nylon or another electrically insulating material to maintain electrical isolation of the interior portions of the slices 101-103.

[0034] The surface of the mating region 1105 includes a number of feedthroughs 1115 for passing connectors 1120 (wires, cables, etc.) to the internal components (such as one or more heat-generating components 405) of the slices 101-103. When the slices 101-103 are connected to the backplane assembly 120, the feedthroughs 1115 can align with corresponding feedthroughs 125 of the backplane assembly 120 to form a hermetic seal, thus ensuring electrical isolation of the internal components.

[0035] 1-11 illustrate an example TCEI system 100 and associated details, various modifications may be made to Figures 1-11. For example, TCEI system 100 and its individual components may have any suitable size, shape, and dimensions. In addition, various components of TCEI system 100 may be combined, further subdivided, duplicated, rearranged, or omitted, and additional components may be added according to particular needs.

[0036] Figure 12 illustrates an exemplary method 1200 for assembling a TCEI system according to the present disclosure. For ease of explanation, the method 1200 is described as being performed using the TCEI system 100 of Figures 1-3. However, the method 1200 may be used with other suitable devices or systems.

[0037] As shown in Figure 12, in step 1202, a first slice and a second slice are provided. This may include, for example, providing a ROADM and hotel power slice 101 and at least one of the accessory slices 102-103. Each slice may include a housing formed of an electrically insulating material, a ceramic plate disposed at each end of the housing, and an end plate disposed on each of the ceramic plates. Each end plate may be formed of a thermally conductive material.

[0038] In step 1204, the slices are coupled together. This may include, for example, coupling together the ROADM and hotel power slice 101 and at least one of the accessory slices 102-103. When the slices are coupled together, for example, one end plate of a first slice may be aligned and contacted with one end plate of a second slice such that both end plates 135 are aligned.

[0039] In step 1206, a backplane assembly is attached to the first slice and the second slice. This may include, for example, attaching the backplane assembly 120 to the ROADM and hotel power slice 101 and the accessory slices 102-103. When the first slice, second slice, and backplane assembly are assembled together, the TCEI system 100 may have a substantially cylindrical overall shape.

[0040] Although Figure 12 illustrates one example of a method 1200 for assembling a TCEI system, various modifications may be made to Figure 12. For example, although shown as a series of steps, various steps illustrated in Figure 12 may overlap, occur in parallel, occur in a different order, occur multiple times, some steps may be combined or eliminated, and additional steps may be added depending on particular needs.

[0041] It may be advantageous to set out definitions of certain words and phrases used throughout this patent document. The terms "include" and "comprise" and their derivatives mean an open-ended inclusion. The term "or" means inclusive and / or. The phrase "associated with" and its derivatives means including, contained within, interconnected with, containing, contained within, connected with, coupled to or with, communicable with, coordinated with, interleaved, juxtaposed with, adjacent to, coupled to or with, having, having the characteristic of, having a relationship to or with, and the like. The phrase "at least one of," when used in conjunction with a list of items, means that one or more different combinations of the listed items may be used, and only one item in the list may be required. For example, "at least one of A, B, and C" includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A, B, and C.

[0042] The description in this application should not be construed as implying that any particular element, step, or function is an essential or critical element that must be included in the scope of the claims. The scope of the claimed subject matter is defined solely by the allowed claims. Moreover, no claim is intended to invoke 35 U.S.C. §112(f) with respect to any of the appended claims or claim elements, except where the precise words "means for" or "step for" are expressly used in a particular claim, followed by a participial phrase identifying the function. The use of terms such as, but not limited to, "mechanism," "module," "device," "unit," "component," "element," "member," "apparatus," "machine," or "system" in the claims is understood and intended to refer to structures known to those skilled in the relevant art, as further modified or emphasized by the features of the claims themselves, and is not intended to invoke 35 U.S.C. §112(f).

[0043] While this disclosure has described certain embodiments and generally associated methods, modifications and permutations of these embodiments and methods will be apparent to those skilled in the art. Thus, the above description of exemplary embodiments does not define or constrain this disclosure. Other modifications, substitutions, and alterations are possible without departing from the spirit and scope of this disclosure, as defined by the following claims.

Claims

1. a first slice and a second slice coupled to each other, each slice comprising: a housing formed of an electrically insulating material; a ceramic plate disposed at each end of the housing; an end plate disposed on each of the ceramic plates, each end plate being formed from a thermally conductive material; the first slice and the second slice, a backplane assembly coupled to the first slice and the second slice; Equipped with Each slice is disposed within the housing. at least one electrical component configured to generate thermal energy upon operation; an internal heat sink disposed within the slice and configured to transfer the thermal energy from the at least one electrical component to the ceramic plate; The system further comprises:

2. the housing of each slice comprises nylon; The system of claim 1 .

3. Each end plate comprises an aluminum alloy. The system of claim 1 .

4. one end plate of the first slice is aligned with and in contact with one end plate of the second slice; The system of claim 1.

5. the first slice, the second slice and the backplane assembly are arranged such that the system has a substantially cylindrical overall shape. The system of claim 1 .

6. the backplane assembly including one or more feedthroughs that align with corresponding feedthroughs in at least one of the slices to form a hermetic seal; The system of claim 1 .

7. A hotel power slice and a plurality of accessory slices coupled together, each slice comprising: a housing formed of an electrically insulating material; a ceramic plate disposed at each end of the housing; an end plate disposed on each of the ceramic plates, each end plate being formed from a thermally conductive material; the hotel power slice and the plurality of accessory slices; a backplane assembly coupled to the hotel power slice and the plurality of accessory slices; Equipped with Each slice is disposed within the housing. at least one electrical component configured to generate thermal energy upon operation; an internal heat sink disposed within the slice and configured to transfer the thermal energy from the at least one electrical component to the ceramic plate; The system further comprises:

8. the housing of each slice comprises nylon; The system of claim 7.

9. Each end plate comprises an aluminum alloy. The system of claim 7.

10. one end plate of the hotel power slice is aligned with and in contact with one end plate of a first accessory slice of the plurality of accessory slices; The system of claim 7.

11. the hotel power slice, the plurality of accessory slices and the backplane assembly are arranged such that the system has a substantially cylindrical overall shape. The system of claim 7.

12. the backplane assembly including one or more feedthroughs that align with corresponding feedthroughs in at least one of the slices to form a hermetic seal; The system of claim 7.

13. providing a first slice and a second slice, each slice including a housing formed of an electrically insulating material, a ceramic plate disposed at each end of the housing, and an end plate disposed on each of the ceramic plates, each end plate being formed of a thermally conductive material; joining the slices together; attaching a backplane assembly to the first slice and the second slice; Including, Each slice is disposed within the housing. at least one electrical component configured to generate thermal energy upon operation; an internal heat sink disposed within the slice and configured to transfer the thermal energy from the at least one electrical component to the ceramic plate; The method further comprises:

14. the housing of each slice comprises nylon; The method of claim 13.

15. Each end plate comprises an aluminum alloy. The method of claim 13.

16. The step of joining the slices together comprises: aligning one end plate of the first slice with one end plate of the second slice; coupling the one end plate of the first slice to the one end plate of the second slice; The method of claim 13, comprising:

17. the first slice, the second slice and the backplane assembly are arranged to have a substantially cylindrical overall shape. The method of claim 13.

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