Abstract: A multilayer circuit board system or laminated circuit board system for use in a motor controller includes a motherboard, at least one power substrate circuit board, and a capacitor circuit board. The power substrate module includes a mounting area provided in a recess, window or portion of the circuit board where the circuit board is only a single layer thick. The single circuit board layer at the mounting area provides a heat conductive yet highly electrically insulated mounting area for receiving a heat sink. The heat sink can be mounted on a side opposite the electrical device. The capacitor circuit board, power substrate circuit board, and mother circuit board are interconnected without the use of external connectors or wires. A flexible circuit board layer or SCM.TM. interconnect interface allows the circuit boards to be connected solely by printed circuit (PC) wires.

Abstract: A multilayer circuit board or laminated circuit board for use in a motor controller is described. The multilayer circuit board is preferably utilized as a power substrate module. The power substrate module includes a mounting area provided in a recess, window or portion of the circuit board where the circuit board is only a single layer thick. The insulated mounting area is provided in a blind via in the multilayer circuit board. The single circuit board layer at the mounting area provides a heat conductive yet highly electrically insulated mounting area for receiving a heat sink. The heat sink can be mounted on a side opposite the electrical device. The heat sink may be standard heat sink or a copper coil directly soldered to the circuit board. The multilayer circuit board includes an enhanced conductive layer for receiving the surface mount device. The enhanced conductive layer preferably includes an insulative frame which holds copper slugs.

Abstract: A controller for driving an AC motor includes a rectifying circuit, an inverting circuit coupled to the rectifying circuit via a DC bus, a control circuit for commanding operation of the inverting circuit, a logic circuit for directing operation of the control circuit in accordance with a predetermined control routine and a power supply circuit for powering the logic and drive circuitry. At least the rectifying circuit and the inverting circuit are supported on a power substrate module, while the control circuit is supported on a separate control circuit board. The control circuit board is mounted on and coupled to the power substrate module via conductors. Incoming AC power and control signals are transmitted to and controlled AC power is transmitted from the power substrate module via the conductors through the control circuit board. Separation of the circuitry between the power substrate module and the control circuit board permits significant reduction in the footprint of the controller.

Abstract: A rigid-flex multilayer circuit board or laminated circuit board includes an insulated mounting area for a surface mount package. The mounting area is provided in a recess or portion of the circuit board where the circuit board is only a single flexible circuit board layer thick. The insulated mounting area is provided in a blind via in the multilayer circuit board. The insulating medium associated with the single flexible circuit board layer is less than 2.0 mils thick and includes polyimide. The single flexible circuit board layer provides a heat conductive yet highly electrically insulative mounting area for receiving a heat sink. The heat sink can be mounted on a side opposite the electrical device. The heat sink may be a standard heat sink or a copper coil directly soldered to the circuit board. The heat sink mounting area eliminates the need for bolts, nuts, brackets, and an additional insulating layer necessary to insulate power semiconductor components.

Abstract: A multilayer circuit board or laminated circuit board includes an insulated mounting area for a surface mount package. The mounting area is provided in a recess or portion of the circuit board where the circuit board is only a single layer thick. The insulated mounting area is provided in a blind via in the multilayer circuit board. The insulating medium associated with the single layer provides a heat conductive yet highly electrically insulative mounting area for a heat sink. The heat sink may be mounted on a side opposite the electrical device. The heat sink may be a standard heat sink or a copper coil directly soldered to the circuit board. The heat sink mounting advantageously eliminates the need for bolts, nuts, brackets, and an additional insulating layer necessary to insulate power semiconductor components.

Abstract: A controller for driving an electric motor includes a rectifying circuit for converting AC power from a source to DC power, an inverting circuit coupled to the rectifying circuit via a DC bus for converting the DC power to controlled AC power in response to control signals and control circuitry for generating control signals for driving the inverting circuit in accordance with a preset control routine. The rectifying and inverting circuits are included in a power substrate module, while the control circuitry is included on a control circuit board separate from the power substrate module. The control circuit board is coupled to the power substrate module via a plurality of conducting pins and the controller circuitry is housed in an enclosure. A plurality of terminal conductors are supported on the control circuit board for transmitting power to and from the power substrate module via the conducting pins through the control circuit board.

Abstract: A method for interrupting electrical power between two conductors is provided, including biasing an electrically conductive element into a conducting position between two contact regions of the conductors. The contact regions are preferably portions of arc runners coupled to the conductors. The conductors surround a magnetic core that generates an electromagnetic field due to current in the conductors. The conductive element is repelled to a non-conducting position by the electromagnetic field in response to an overcurrent condition in the conductors. A secondary response mechanism is moved in response to the overcurrent condition to maintain the conductive element in the non-conducting position. For more gradually occurring overcurrent conditions, the secondary response mechanism is attracted toward the core, displacing the conductive element to the non-conducting position.

Abstract: A circuit interrupter provides a conducting path between two conductors and interrupts the conducting path in response to overcurrent conditions in the conductors. The interrupter includes a magnetic core around which the conductors are disposed. Each conductor is electrically coupled to an arc runner and a spanner is biased into contact with the arc runners to compete a conducting path between the conductors. A secondary response mechanism is provided adjacent to the core and includes arms extending around the core and a magnetic body. In response to overcurrent conditions of a first magnitude the body of the secondary response mechanism is attracted to the core causing the arms to displace the spanner out of contact with the arc runners. In response to overcurrent conditions of a second magnitude, such as due to direct short circuits, the spanner is repelled rapidly to a non-conducting position and the secondary response mechanism is attracted to the core to hold the spanner in the non-conducting position.

Abstract: An electrical contactor including a control system for regulating the voltage applied to the contactor's coil. The control system is adapted for gradually increasing the applied voltage and the resultant current through the coil so that contact closure takes place under controlled conditions. The control system enables the contacts in the contactor to be closed with a minimum of contact bounce upon activation of the contactor.

Abstract: A mechanism for an overload relay or the like employs a contact bar that is held in a reset position by magnetic attraction and in a tripped position by the biasing of a spring. The magnetic attraction effective in the reset condition may be overcome by a countervailing magnetic field developed by a coil driven in turn by overload sensing circuitry, or by the mechanical displacement of the contact bar away from the reset position by any small amount. Resetting is accomplished by another magnetic linkage which also may be subject to the countervailing field of the coil to prevent resetting during an overload condition.

Abstract: A pilot light on a relay or other industrial control module provides human readable information with low frequency modulation and machine readable information at high frequency modulation unintelligible to the human eye. The use of the pilot light eliminates the need for a separate and space consuming human readable display and the modulation method may be a bar code modulation to be readable by commercially available bar code readers.

Abstract: A snow chain traction kit for the drive wheels of a wheelchair, the kit including a number of pairs of attachment strips for each wheel and a traction strap for each pair of strips, each of the straps having a plurality of chains for providing traction on ice or snow and each pair of strips being mounted on opposite sides of the wheels, with the straps wrapped around the tire and being attached to one pair of strips.

Abstract: A method of manufacturing a core for an electrical inductive device. A blind hole is provided through a stack of laminations into which an oil or an epoxy resin adhesive is placed. The blind hole provides a slow release for the oil to the outer surfaces. This obviates the contamination of the outer surfaces of the coil during manufacture as in the case with a dipping procedure. When the epoxy resin adhesive is employed in the blind hole, a wicking action takes place for better fastening of the laminations together. In another embodiment of the fastening feature, epoxy resin adhesive is molded to the outside of the end piece laminations as well as through a passage in the laminations. An improved resulting core is also provided.

Abstract: A conversion kit for connecting a friction drive system for a motorized wheelchair to a positive drive system which includes a cog wheel, a strip of metallic material having a number of cogs stamped at equally spaced intervals and a belt having internal cogs for matingly engaging the cog wheel and metallic strip and the method of conversion.