Abstract: A fan includes an air movement implement including a blade and a motor that drives the air movement implement. The motor includes a rotor that includes an internal diameter heat exchanger and a heat pipe having a first end and a second end, the first end in thermal contact with the internal diameter heat exchanger and the second end in thermal contact with the blade.

Abstract: A power distribution contactor mount, and a power distribution system incorporating the same, include a plurality of electrically and thermally conductive contactor posts operable to connect a contactor lead to a bus bar, a mounting panel face, wherein each of the contactor posts is received in the mounting panel face and extends through the mounting panel face, and a first heat dissipation component mounted on the mounting panel face and thermally connected to each of the contactor posts. The thermal connection is via a thermally conductive and electrically insulative polymer insert, and each of the posts protrudes through the first heat dissipation component.

Abstract: A remote power unit has an inlet duct and an outlet duct in a housing. The inlet and outlet ducts are configured to receive and expel cooling air from the remote power unit. A plurality of slots within the housing each hold a printed wiring board. A door is attached to each of the slots, and each door has a shape thermal memory element. The shape thermal memory element is used to open and close the doors to either allow or prevent cooling airflow from passing along the printed wiring board. In this way, cooling air use is reduced to only those areas where cooling is needed.

Abstract: An electrical contactor assembly is provided including an electrical contactor, an electrical bus bar, and a single panel formed of one more layers of an electrically insulating, thermally conductive material. A plurality of posts protrude through and directly contact the panel. Each of the posts is constructed from an electrically and thermally conductive material. Each post has a first end configured to electrically and thermally connect to the electrical contactor and a second end configured to electrically and thermally connect to the bus bar.

Abstract: An electrical contactor assembly is provided including an electrical contactor, an electrical bus bar, and a panel formed from an electrically insulating material. At least one post protrudes through the panel and is in contact with the electrical bus bar. The at least one post is constructed from an electrically and thermally conductive material. A first end of the at least one post is configured to electrically and thermally connect to the electrical contactor. A heat sink is removably coupled to a second end of the at least one post. The heat sink includes a body having a plurality of fins extending radially outward. A first portion of the plurality of fins extends around a circumference of the body. A second portion of the plurality of fins extends around only a portion of the circumference of the body.

Abstract: Embodiments are directed to obtaining a specification of at least one operational requirement for at least one capacitor, generating a design of the at least one capacitor to satisfy the at least one operational requirement, the design of the at least one capacitor comprising a plurality of layers and a first integrated busbar coupled to at least a portion of the layers, and based on the design, manufacturing the at least one capacitor by utilizing an additive manufacturing technique.

Abstract: A plurality of cores are arranged in a loop between an inner wall and an outer wall. A gap filler is arranged circumferentially between each of the plurality of cores. A high thermal conductivity potting material is arranged around both the inner and outer edges of the core segments. A winding wraps around each of the plurality of core segments. The windings may be embedded within the high thermal conductivity potting material.

Abstract: An electrical contactor assembly is provided including an electrical bus bar and at least one electrical contactor. The electrical bus bar includes a layer of insulation, a layer of copper, and a composite core having at least one wire embedded therein. The wire is configured to locally reduce thermal strain. The at least one electrical contactor is mounted to the layer of copper through an opening in the layer of insulation. The electrical contactor and the bus bar are thermally and electrically connected.

Abstract: An electronic component assembly includes a housing that provides a cavity filled with a cooling fluid that has a liquid phase and a vapor phase. An electronic element is arranged in the cavity and is configured to generate heat. A wicking material is arranged in the cavity between the housing and the electronic device. The cavity provides a gap adjacent to the wicking material. The wicking material is configured to absorb the liquid phase, and the vapor phase is provided in the gap.

Abstract: A fan motor controller for a turbine engine comprises a component mounting base and a plurality of fan controller components mounted to the component mounting base. The component mounting base comprises a plurality of sections that are configured to extend circumferentially around a fan inner housing.

Abstract: A power distribution cabinet includes a housing having walls that define an interior space for housing electric components. A capacitive sensor is located on an interior surface of one or more of the walls. The capacitive sensor includes a first conductive layer located proximate to the interior surface of the wall, a second conductive layer located distal from the interior surface of the wall, and a dielectric layer located between the first and second conductive layers. First and second output terminals are connected to the first and second conductive layers of the capacitive sensor to provide an output representative of displacement current within the power distribution cabinet.

Abstract: A method of manufacturing a nonconductive liquid cooled back iron heat exchanger to house a conductive cooling liquid is disclosed. This method may include forming layers of material via additive manufacturing to create channels for transporting cooling liquid. The layers may be staggered to create electrically insulated liquid cooling channels. This method may include providing cooling liquid from a power electronics cooling system (PECS) heat exchanger via a pressure drop between the PECS heat exchanger back iron heat exchanger. Also described herein is a liquid cooled stator cooling system, including an aircraft cabin air compressor motor. The motor may include a motor housing and a stator core. A liquid cooled back iron heat exchanger may be positioned between the motor housing and the stator core.

Abstract: A heat exchanger includes a pair of opposed, spaced apart heat exchanger plates defining a heat exchanger volume therebetween having an inlet and opposed outlet. A plurality of heat exchanger ribs are included within the heat exchanger volume. Each rib defines a rib body spanning the heat exchanger volume. Each rib body includes a plurality of slits therethrough to define a flow path through the heat exchanger ribs from the inlet to the outlet of the heat exchanger volume. The ribs and slits can be formed using ultrasonic additive manufacturing (UAM), for example.

Abstract: An electrical inductor assembly includes an inductor core having a relatively circular geometry. Also included is a wire guide surrounding and retaining the inductor core, the wire guide having a plurality of slots for retaining and guiding a plurality of wires. Further included is an outer housing surrounding and retaining the wire guide and a substance disposed within at least one of the plurality of slots of the wire guide.

Abstract: A motor driven assembly includes a motor having a motor inlet and a motor outlet, a shaft, and a rotor spaced radially outwards from the shaft. A cooling flow passage is located between the shaft and the rotor. The cooling flow passage fluidly connects the motor inlet and the motor outlet. A compressor is in fluid communication with the motor outlet. The compressor includes a compressor outlet that is in fluid communication with the motor inlet.

Abstract: An electrical assembly for a motor controller is disclosed that includes an electrical lead. The electrical lead has a conductive trace within an insulating material and that extends a length between first and second ends. An electrical pad is in electrical continuity with and extends from the conductive trace through the insulating material at the first end. The pad includes an aperture providing a securing feature. An electrical component is supported by and integral with the second end, in one example. The electrical component is in electrical continuity with the conductive trace at the second end. A bus bar provides a joint having a first cross-sectional area. The electrical lead is flexible and is removably secured to the joint by the securing feature to provide electrical continuity from a capacitor to the bus bar. The flexible electrical lead has a second cross-sectional area substantially less than the first cross-sectional area.

Abstract: An electrical contactor assembly is provided including an electrical contactor, an electrical bus bar, and a panel formed from an electrically insulating material. At least one post protrudes through the panel and is in contact with the electrical bus bar. The at least one post is constructed from an electrically and thermally conductive material. A first end of the at least one post is configured to electrically and thermally connect to the electrical contactor. A heat sink is removably coupled to a second end of the at least one post. The heat sink includes a body having a plurality of fins extending radially outward. A first portion of the plurality of fins extends around a circumference of the body. A second portion of the plurality of fins extends around only a portion of the circumference of the body.

Abstract: A fan includes an air movement implement including a blade and a motor that drives the air movement implement. The motor includes a rotor that includes an internal diameter heat exchanger and a heat pipe having a first end and a second end, the first end in thermal contact with the internal diameter heat exchanger and the second end in thermal contact with the blade.

Abstract: A driver system, cooling apparatus for a driver system, and method are provided. The driver system includes a driver, a device configured to move a cooling fluid, and a shroud disposed at least partially over the driver. The shroud includes a plurality of inlet orifices and a plurality of outlet orifices in fluid communication with the device, and a plurality of fins extending at least partially between the shroud and the driver, at least partially in the driver, or both, the plurality of fins being spaced apart and defining flowpaths therebetween, wherein the flowpaths communicate with the inlet orifices and the outlet orifices.

Abstract: An electric machine includes a stator having an outer circumference. Spaced apart first walls are arranged about the outer circumference and provide generally parallel first channels. A second wall adjoins the first wall and is arranged about the outer circumference providing a second channel in fluid communication with the first channels, thus, providing a tortuous fluid flow path about the circumference. The first and second channels have an inner surface. A structure is provided within at least one of the first and second channels. The structure has an outer surface spaced radially outward from the inner surface and at least partially defines the tortuous flow path between the outer and inner surfaces. The stator includes an end turn. An end cap extends axially and radially outward from the stator and provides an enclosure about the end turn in fluid communication with the exit associated with the flow path.