Motor Controller Cold Plate Assembly With Through-Plate Terminals

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Solution Overview

Problem

Conventional motor controller designs with output terminals protruding from the cold plate result in increased thickness, poor heat dissipation, and difficulty in assembly due to perpendicular connections, leading to slow cooling and potential wire sheath melting during high power output.

Innovation Solution

A motor controller and cold plate assembly design with output copper pillars passing through the cold plate, utilizing a potting component to enhance structural strength and heat dissipation, and allowing adjustable wiring terminal connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If output terminal structure is disposed above the cold plate, then terminal connection is simplified, but assembly thickness increases and heat dissipation efficiency deteriorates

Engineering Contradiction:

Improveterminal connectionVSAvoidassembly thickness

Core Design Contradiction:

Ease of operationVSLength of stationary object

Solution Approach 1:

The patent inverts the conventional terminal structure arrangement by passing copper pillars vertically through the cold plate from top to bottom, rather than disposing terminals only above the cold plate. This inversion allows terminals to be connected at the bottom side, simplifying wiring while reducing assembly thickness and improving heat dissipation efficiency.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If output terminal structure is disposed above the cold plate, then terminal connection is simplified, but heat dissipation efficiency deteriorates

Engineering Contradiction:

Improveterminal connectionVSAvoidheat dissipation efficiency

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If reverse terminal output structure is used, then terminal connection is improved, but assembly complexity increases

Engineering Contradiction:

Improveterminal connectionVSAvoidassembly structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent segments the terminal structure into distinct components: copper pillars passing through the cold plate, terminal bases mounted on the PCB, and separate connection elements. This segmentation allows for modular assembly and simplified manufacturing while achieving improved terminal connection functionality.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Reduces the overall thickness of the assembly, improves heat dissipation efficiency, and simplifies assembly by enabling vertical screw connections and adjustable wiring directions, while providing structural support and waterproofing.

Implementation Method 1

the fourth surface of the PCB is attached to the first surface of the cold plate for heat dissipation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the potting component is further formed to enhance the supporting strength between the conductive component and the cold plate

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

cold plates are wildly used in the motor controllers of electric vehicles

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250386452A1Motor controller and cold plate assembly

Publication Date: 2025.12.18 DELTA ELECTRONICS INC(CN)

AI summary

A motor controller and cold plate assembly is disclosed and includes a cold plate, a PCB, a terminal base, a conductive component and a wiring terminal. The cold plate includes a first surface and a second surface opposite to each other, and a through hole. The though hole passes through the first surface and the second surface. The PCB includes a third surface and a fourth surface opposite to each other, and an opening. The fourth surface is attached to the first surface. The opening and the through hole are spatially aligned and communicated to each other. The terminal base is spatially corresponding to the opening and the through hole. The conductive component passes through the through hole, is spaced apart from the cold plate and engaged with the terminal base. The wiring terminal is connected to the conductive component, and extended along the second surface of the cold plate.