US 10,541,081 B2Granted

Method for potting an electrical component

OwnerEdward Handy, Grant A. MacLennan +1inventors

InventorsEdward Handy, Grant A. MacLennan, Hans Wennerstrom

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Abstract

A high frequency inductor filter cooling apparatus, method of manufacture, and method of use thereof is described. In one embodiment, an inductor is potted in an epoxy-silica mixture to facilitate thermal transfer from the inductor. The inductor is optionally used with a capacitor to filter/invert/convert power. The inductor optionally comprises a distributed gap core and/or a powdered core material. In one example, a minimum carrier frequency used with the filter is above that usable by a traditional wound iron-steel inductor, such as greater than seven hundred or ten thousand Hertz at fifty or more amperes. Optionally, the inductor is used in an inverter/converter apparatus in conjunction with a notched low-pass filter, a low pass filter combined with a notch filter and a high frequency roll off filter, and/or one or more of a silicon carbide, gallium arsenide, and/or gallium nitride based transistor.

Claims6

Dependent claims

A method for potting an electrical component, comprising the steps of:

placing said electrical component in a housing;
preheating both a potting agent and a heat transfer agent to in excess of ninety-five degrees Fahrenheit;
mixing said potting agent, comprising a thermal conductivity of less than 0.3 W/m-K, with said heat transfer agent, comprising a thermal conductivity of greater than 0.5 W/m-K, to form a potting material;
and
dispensing said potting material about said electrical component in said housing to form a potted electrical component, said potting material positioned about said electrical component, within said housing, and within a quarter inch of said electrical component,
wherein said heat transfer agent comprises particles, wherein ninety-five percent of said particles comprise a diameter of less than 1500 micrometers,
wherein said potting agent comprises at least thirty percent by mass of said potting material, and
wherein said heat transfer agent comprises at least thirty percent by mass of said potting material.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/939,167Filed 28 Mar 2018 · division
Priority: 5 Apr 2007
Published: US 2019/0027305 A124 Jan 2019
Granted: 21 Jan 2020
Term ends: Not estimatedThe source records don’t support an estimate.

Classification23 codes

H01F 41/005
Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially…:…
H01F 27/085
Cooling ; Ventilating: cooling by ambient air
H01F 27/255
Magnetic cores: made from particles
H01F 27/266
Fastening parts of the core together; Fastening or mounting the core on casing or support: fastening or mounting the core on casing or support

Family

Application60/910,333Us provisional application · filed 5 Apr 2007
Application12/098,880Parent of this continuation-in-part · filed 7 Apr 2008
Application13/107,828Parent of this continuation-in-part · filed 13 May 2011
Application13/470,281Parent of this continuation-in-part · filed 12 May 2012
Application13/954,887Parent of this continuation-in-part · filed 30 Jul 2013
Application14/260,014Parent of this continuation-in-part · filed 23 Apr 2014
Application14/988,605Parent of this division · filed 5 Jan 2016
US 2019/0027305 A1Pre-grant publication · published 24 Jan 2019
US 10,312,018 B2Parent of this division
US 9,590,486 B2Parent of this continuation-in-part
Application14/988,605Parent of this continuation-in-part
US 9,257,895 B2Parent of this continuation-in-part
US 8,902,034 B2Parent of this continuation-in-part
US 8,373,530 B2Parent of this continuation-in-part
US 7,973,628 B1Parent of this continuation-in-part
US 2012/0223792 A1Published application
US 2012/0286914 A1Published application
US 2015/0035466 A1Published application
US 2015/0310977 A1Published application
US 2016/0203907 A1Published application
US 10,541,081 B2This patent

From the US filing history. Foreign family members aren’t listed.