Protective bracket in power electronic devices and systems

Abstract

A protective bracket includes a body having one or more electrical contact apertures for one or more electrical contacts, and for each of the one or more electrical contact apertures, an anti-rotation housing extending from the body around that corresponding electrical contact aperture. The protective bracket is made of non-conductive material. In some cases, the nonconductive material includes vibration-absorbing properties. In some cases, the protective bracket is designed to fit in a power electronic device. In some cases, the power electronic device is a converter, an inverter, an eHeater, or a battery device. In some cases, each of the anti-rotation housing is configured to prevent short-circuiting and electrical leakage between a corresponding electrical contact and an inner portion of the power electronic device and is further configured to prevent rotation of an electrical contact nut secured to a corresponding electrical contact.

Description

PROTECTIVE BRACKET IN POWER ELECTRONIC DEVICES AND SYSTEMSCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present invention claims the benefit of India Provisional Application Number 202311059268, filed on September 4, 2023, which is hereby incorporated by reference in its entirety, including any figures, tables, and drawings.BACKGROUND

[0002] In power electronics devices and systems, such as inverter, converter, battery, and eHeater devices and systems, electrical connections are required. These systems are often secured in place by metallic nuts and bolts (or other metallic securing mechanisms) and protected by a metallic housing to protect the systems from damage and unwanted electrical leakage. However, these metallic securing mechanisms and housings create the possibility for short-circuiting of these systems. Therefore, there is a need for solutions that prevent shortcircuiting and unwanted electrical leakage in power electronic devices and systems.BRIEF SUMMARY

[0003] A protective bracket for use in power electronic devices and systems, such as eHeater, converter, inventor, and / or battery devices and systems, is provided. Advantageously, the protective bracket ensures proper contact and / or positioning with connection mechanisms (e.g., metallic nuts and bolts), prevents unwanted rotation and / or loosening of the connection mechanisms, prevents wear and tear to surrounding materials (e.g., such as a printed circuit board (PCB)), and prevents short circuiting and / or leakage of current by separating metallic parts with the non-conductive material of the protective bracket.

[0004] A protective bracket includes a body having one or more electrical contact apertures for a one or more electrical contacts, and, for each of the one or more electrical contact apertures, an anti-rotation housing extending from the body around that corresponding electrical contact aperture. The protective bracket is made of non-conductive material.

[0005] In some cases, the body is sized to fit over a portion of a printed-circuit-board (PCB) that is electrically coupled to the one or more electrical contacts. In some cases, the body is further sized to fill a void between the PCB and an inner portion of a power electronic device. In some cases, the anti-rotation housing is configured to prevent short-circuiting and electrical leakage between a corresponding electrical contact of the one or more electrical contacts and an inner portion of a power electronic device. In some cases, each of the anti -rotation housingis configured to prevent rotation of an electrical contact nut of the secured to a corresponding electrical contact of the one or more electrical contacts. In some cases, the protective bracket further includes a plurality of connection features around an edge of the body. In some cases, the plurality of connection features include a plurality of screw apertures for screws or bolts. In some cases, the one or more electrical contact apertures include one or more terminal apertures for one or more terminals. In some cases, the protective bracket further includes a ground terminal aperture for a ground terminal. In some cases, the non-conductive material includes vibration-absorbing properties.

[0006] A power electric device includes an inner portion that includes a conductive housing, a top cover, and a protective bracket. The top cover includes a printer circuit board (PCB) positioned on an inside surface of the top cover and one or more electrical contacts disposed on an outside surface of the top cover and electrically coupled to the PCB. The protective bracket can include one or more features described above.

[0007] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figures 1A-1C illustrate a top cover of a DC / DC converter.

[0009] Figures 2A and 2B illustrate cross-sectional views of a top cover of a DC / DC converter.

[0010] Figures 3A-3C illustrate exploded cross-sectional views of a top cover of a DC / DC converter.

[0011] Figures 4A and 4B illustrate a protective bracket used in a top cover of a DC / DC converter.DETAILED DESCRIPTION

[0012] A protective bracket for use in power electronic devices and systems, such as eHeater, converter, inventor, and / or battery devices and systems is provided. Advantageously, the protective bracket ensures proper contact and / or positioning with connection mechanisms (e.g., metallic nuts and bolts), prevents unwanted rotation and / or loosening of the connection mechanisms, prevents wear and tear to surrounding materials (e.g., such as a printed circuitboard (PCB)), and prevents short circuiting and / or leakage of current by separating metallic parts with the non-conductive material of the protective bracket.

[0013] Although examples are described herein with respect to a DC / DC converter, it should be understood that other types of converter, inverter, eHeater, and battery systems can include some or all of the features described herein.

[0014] Figures 1A-1C illustrate a top cover of a DC / DC converter. Referring to Figures 1A and IB, a first electrical contact assembly 104 and a second electrical contact assembly 106 protrude through electrical contact assembly apertures 108 in an outer portion 102 of a top cover 100 of a DC / DC converter. In this example, the electrical contact assemblies 104, 106 are terminal assemblies, however, other electrical contact assemblies can be used in conjunction with the protective bracket described herein. In this example, each of the electrical contact assemblies 104, 106 include a terminal (as illustrated in Figures 2A, 2B, and 3A-3C), a protective cap 110 that is placed over the terminal, and a connector block 112. In some cases, a ground terminal 114 is included between the electrical contact assemblies 104, 106 and protrudes through a ground terminal aperture 116 of the outer portion 102 of the top cover 100. A line from X to X’ is also illustrated that represents a cross-sectional line through the top cover 100 (e.g., as represented in Figures 2A, 2B, and 3A-3C). Referring to Figure 1C, aprinted circuit board 118 and a protective bracket 120 are coupled to a bottom portion 122 of the top cover 100.

[0015] Figures 2A and 2B illustrate cross-sectional views of a top cover of a DC / DC converter. Figures 3A-3C illustrate exploded cross-sectional views of a top cover of a DC / DC converter. For example, these cross-sectional views can represent a cross-sectional view of the top cover 100 of a DC / DC converter through the line from X to X’ in Figure IB. Referring to Figures 2A, 2B, and 3A-3C, a top cover 200 of a DC / DC converter includes an outer portion 202. Figures 2A and 2B also illustrate an inner portion 204 of a DC / DC converter. The top cover 200 further includes one or more electrical contact assembly apertures 206. A first electrical contact assembly 208 and a second electrical contact assembly 210 each individually protrude through a corresponding one of the corresponding electrical contact assembly apertures 206 and are disposed on an outside surface, such as the outer portion 102, of the top cover 200 of the DC / DC converter. For example, the electrical contact assemblies 208, 210 in the top cover 200 can include a positive terminal assembly and a negative terminal assembly.

[0016] Each electrical contact assembly 208, 210 includes a protective cap 212, a connector block 214, a terminal 216, a fuse 218, and a nut 220. In some cases, the fuse 218 is a marinerated battery fuse (MRBF). In some cases, the terminal 216 is a bolt. A printed circuit board(PCB) 222 is electrically coupled to each electrical contact assembly 208, 210. In some cases, the PCB 222 is electrically coupled around the terminal 216 of each electrical contact assembly 208, 210 and above the fuse 218 of each terminal assembly 208, 210 and / or on an inside surface, such as the inner portion 204, of the top cover 200. In some cases, a ground terminal 226 is included between each of the electrical contact assemblies 208, 210 and protrudes through a ground terminal aperture 228 of the outer portion 202 of the top cover 200. The nut 220 secures each fuse 218 and the PCB 222 in the top cover 200 of the DC / DC converter and is secured to the terminal 216.

[0017] A protective bracket 224 is placed over at least a portion of the PCB 222. In some cases, the protective bracket 224 is sized to fit over a portion of the PCB 222 that is electrically coupled to the electrical contact assemblies 208, 210, 226. The protective bracket 224 is described in further detail with respect to Figures 4A and 4B below. In some cases, the protective bracket 224 is sized to fill all space between the PCB 222 and the inner portion 204 of the DC / DC converter. By sizing the protective bracket 224 to fill all the space between the PCB 222 and the inner portion 204 of the DC / DC converter, issues caused by vibration during operation of the DC / DC converter can be lessened and / or eliminated. The inner portion 204 of the DC / DC converter includes a conductive housing. Accordingly, the protective bracket 224 also prevents short-circuiting and electrical leakage with the inner portion 204 of the DC / DC converter.

[0018] Figures 4A and 4B illustrate a protective bracket used in a top cover of a DC / DC converter. Referring to Figures 4A and 4B, a protective bracket 400 includes a body 402 having one or more terminal apertures 404 for terminals (e.g., as illustrated in Figures 2A, 2B, and 3A- 3C). The protective bracket 400 further includes, for each of the one or more terminal apertures 404, an anti-rotation housing 408 extending from the body 402 around that corresponding terminal aperture 404. The protective bracket 400 is made of non-conductive material. In some cases, the non-conductive material used to form the protective backet 400 includes vibrationabsorbing properties, such as, for example, rubber or other similar non-conductive materials that include vibration-absorbing properties.

[0019] In some cases, non-conductive material used to form the protective bracket 400 includes polycarbonate, acrylic or polymethyl methacrylate, polycarbonate, polyethylene, polyethylene terephthalate, polyvinyl chloride, acrylonitrile-butadiene-styrene, polymers including plastics and / or resins, rubber, and / or glass.

[0020] In some cases, the body 402 is sized to fit over a printed-circuit-board (e.g., as illustrated in Figures 2A, 2B, and 3A-3C). In some cases, the body 402 is sized to fill spaceand / or a void between the printed-circuit-board and an inner portion of a converter, inverter, eheater, or battery (e.g., as illustrated with respect to the DC / DC converter in Figures 2A and 2B). In some cases, the one or more electrical contact apertures 404 that are formed within the body 402 are sized and / or shaped to provide a secure (e.g., tight and / or snug) fit around the electrical contact (e.g., terminal 216) and / or the fuse (e.g., fuse 218) so that the protective bracket snaps and / or locks into place around the electrical contact and / or fuse during insertion / placement of the protective bracket 400. In some cases, the protective bracket 400 further includes a plurality of connection features 410 around an edge 412 of the body 402. In some cases, the plurality of connection features 410 include a plurality of screw apertures for screws and / or bolts. In some cases, when screws and / or bolts and / or other attachment mechanisms are inserted into the plurality of connection features 410, the protective bracket 400 is snugly and / or securely pressed against the PCB and / or terminals such that issues caused by vibration during operation of the DC / DC converter, such as degradation of the PCB and / or rotation of a terminal nut, is lessened and / or eliminated.

[0021] In some cases, the anti-rotation housing 408 is configured to prevent short-circuiting and electrical leakage with an inner portion of a power electronic device. For example, the antirotation housing 408 provides a layer of non-conductive material between the terminal assembly and an inner portion of a converter, inverter, eHeater, or battery. In some cases, the anti-rotation housing 408 is configured to prevent rotation of a terminal nut (e.g., nut 220) of the terminal. For example, the anti-rotation housing 408 provides a structural housing around a nut secured to a terminal that prevents the nut from rotating during use (e.g., in which there may be vibration and movements that affect power electronic devices and systems). In some cases, the body 402 of the protective bracket 400 further includes a ground terminal aperture 414 for a ground terminal (e.g., as illustrated in Figures 2A and 2B). In some cases, the ground terminal aperture 414 that is formed within the body 402 is sized and / or shaped to provide a secure (e.g., tight and / or snug) fit around the ground terminal (e.g., ground terminal 226) so that the protective bracket snaps and / or locks into place around the ground terminal during insertion / placement of the bracket 400.

[0022] Although examples are described herein with respect to a 48V to 12V DC / DC converter, it should be understood that other types of converter, inverter, eHeater, and battery systems can include some or all of the features described herein. Furthermore, some or all of the features described herein may be altered for implementation in a specific type of converter, inverter, eHeater, and / or battery system(s) and still be within the scope of this disclosure.

[0023] Clause 1. A protective bracket comprising: a body having one or more electrical contact apertures for one or more electrical contacts; and for each of the one or more electrical contact apertures, an anti-rotation housing extending from the body around that corresponding electrical contact aperture, wherein the protective bracket is made of non-conductive material.

[0024] Clause 2. The protective bracket of clause 1, wherein the body is sized to fit over a portion of a printed-circuit-board (PCB) that is electrically coupled to the one or more electrical contacts.

[0025] Clause 3. The protective bracket of clause 1 or 2, wherein the body is further sized to fill a void between the PCB and an inner portion of a power electronic device.

[0026] Clause 4. The protective bracket of any clause 1-3, wherein each of the anti -rotation housing is configured to prevent short-circuiting and electrical leakage between a corresponding electrical contact of the one or more electrical contacts and an inner portion of a power electronic device.

[0027] Clause 5. The protective bracket of any clause 1-4, wherein each of the anti -rotation housing is configured to prevent rotation of an electrical contact nut secured to a corresponding electrical contact of the one or more electrical contacts.

[0028] Clause 6. The protective bracket of any clause 1-5, further comprising a plurality of connection features around an edge of the body.

[0029] Clause 7. The protective bracket of any clause 1-6, wherein the plurality of connection features comprise a plurality of screw apertures for screws or bolts.

[0030] Clause 8. The protective bracket of any clause 1 -7, wherein the one or more electrical contact apertures comprise one or more terminal apertures for one or more terminals.

[0031] Clause 9. The protective bracket of any clause 1-8, further comprising a ground terminal aperture for a ground terminal.

[0032] Clause 10. The protective bracket of any clause 1-9, wherein the nonconductive material includes vibration-absorbing materials.

[0033] Clause 11. A power electronic device comprising: an inner portion comprising a conductive housing; a top cover comprising: a printed circuit board (PCB) positioned on an inside surface of the top cover; and one or more electrical contacts disposed on an outside surface of the top cover and electrically coupled to the PCB; and a protective bracket comprising: a body having one or more electrical contact apertures for one or more electrical contacts; and for each of the one or more electrical contact apertures, an anti-rotation housing extending from the body around that corresponding electrical contact aperture, wherein the protective bracket is made of non-conductive material.

[0034] Clause 12. The device of clause 11, wherein the body of the protective bracket is sized to fit over a portion of the PCB that is electrically coupled to the one or more electrical contacts.

[0035] Clause 13. The device of clause 11 or 12, wherein the body of the protective bracket is further sized to fill a void between the PCB and the inner portion.

[0036] Clause 14. The device of any clause 11-13, wherein each of the anti-rotation housing of the protective bracket is configured to prevent short-circuiting and electrical leakage between a corresponding electrical contact of the one or more electrical contacts and the inner portion.

[0037] Clause 15. The device of any clause 11-14, wherein each of the anti-rotation housing of the protective bracket is configured to prevent rotation of an electrical contact nut secured to a corresponding electrical contact of the one or more electrical contacts.

[0038] Clause 16. The device of any clause 11-15, wherein the protective bracket further comprises a plurality of connection features around an edge of the body of the protective bracket.

[0039] Clause 17. The device of any clause 11-16, wherein the plurality of connection features comprise a plurality of screw apertures for screws or bolts.

[0040] Clause 18. The device of any clause 11-17, wherein the one or more electrical contact apertures of the body of the protective bracket comprise one or more terminal apertures for one or more terminals.

[0041] Clause 19. The device of any clause 11-18, wherein the nonconductive material of the protective bracket includes vibration-absorbing materials.

[0042] Clause 20. The device of any clause 11-19, wherein the power electronic device is a converter, an inverter, an eHeater, or a battery device.

[0043] Although the subject matter has been described in language specific to structural features and / or acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as examples of implementing the claims and other equivalent features and acts are intended to be within the scope of the claims.

Claims

CLAIMSWhat is claimed is:

1. A protective bracket comprising: a body having one or more electrical contact apertures for one or more electrical contacts; and for each of the one or more electrical contact apertures, an anti-rotation housing extending from the body around that corresponding electrical contact aperture, wherein the protective bracket is made of non-conductive material.

2. The protective bracket of claim 1, wherein the body is sized to fit over a portion of a printed-circuit-board (PCB) that is electrically coupled to the one or more electrical contacts.

3. The protective bracket of claim 2, wherein the body is further sized to fill a void between the PCB and an inner portion of a power electronic device.

4. The protective bracket of claim 1, wherein each of the anti -rotation housing is configured to prevent short-circuiting and electrical leakage between a corresponding electrical contact of the one or more electrical contacts and an inner portion of a power electronic device.

5. The protective bracket of claim 1, wherein each of the anti -rotation housing is configured to prevent rotation of an electrical contact nut secured to a corresponding electrical contact of the one or more electrical contacts.

6. The protective bracket of claim 1, further comprising a plurality of connection features around an edge of the body.

7. The protective bracket of claim 6, wherein the plurality of connection features comprise a plurality of screw apertures for screws or bolts.

8. The protective bracket of claim 1, wherein the one or more electrical contact apertures comprise one or more terminal apertures for one or more terminals.

9. The protective bracket of claim 1, further comprising a ground terminal aperture for a ground terminal.

10. The protective bracket of claim 1, wherein the nonconductive material includes vibration-absorbing materials.

11. A power electronic device comprising: an inner portion comprising a conductive housing; a top cover comprising: a printed circuit board (PCB) positioned on an inside surface of the top cover; and one or more electrical contacts disposed on an outside surface of the top cover and electrically coupled to the PCB; and a protective bracket comprising: a body having one or more electrical contact apertures for one or more electrical contacts; and for each of the one or more electrical contact apertures, an anti -rotation housing extending from the body around that corresponding electrical contact aperture, wherein the protective bracket is made of non-conductive material.

12. The device of claim 11, wherein the body of the protective bracket is sized to fit over a portion of the PCB that is electrically coupled to the one or more electrical contacts.

13. The device of claim 12, wherein the body of the protective bracket is further sized to fill a void between the PCB and the inner portion.

14. The device of claim 11, wherein each of the anti -rotation housing of the protective bracket is configured to prevent short-circuiting and electrical leakage between a corresponding electrical contact of the one or more electrical contacts and the inner portion.

15. The device of claim 11, wherein each of the anti -rotation housing of the protective bracket is configured to prevent rotation of an electrical contact nut secured to a corresponding electrical contact of the one or more electrical contacts.

16. The device of claim 11, wherein the protective bracket further comprises a plurality of connection features around an edge of the body of the protective bracket.

17. The device of claim 16, wherein the plurality of connection features comprise a plurality of screw apertures for screws or bolts.

18. The device of claim 11, wherein the one or more electrical contact apertures of the body of the protective bracket comprise one or more terminal apertures for one or more terminals.

19. The device of claim 11, wherein the nonconductive material of the protective bracket includes vibration-absorbing materials.

20. The device of claim 11, wherein the power electronic device is a converter, an inverter, an eHeater, or a battery device.

Images