Abstract: An apparatus includes a substrate layer formed from a pottant material that extends longitudinally in an unwound state. Cores are spaced longitudinally along the substrate layer and joined to the substrate at a first surface. The apparatus further includes pottant segments joined to the cores at a second surface opposite the first surface.

Abstract: A module has a first layer with a plurality of transistors mounted thereon. Circuit traces are configured to communicate current between the transistors outwardly of the module. A second layer is in operable communication with the first layer. A third layer is in operable communication with the second layer. A baseplate is in grounded communication with the third layer. A plurality of ribs are positioned between the third layer and the baseplate. The module is configured to allow fluid to flow between the third layer and the baseplate and around the plurality of ribs. A motor drive and a method are also disclosed.

Abstract: A motor controller is provided including a motor controller housing an air inlet and an air outlet. A plurality of heat generating elements is disposed within the motor control housing. A cooling system includes a cooling device having a fluid sealed therein arranged within the motor control housing. The plurality of heat generating elements is cooled by conduction to the cooling device and by convection from an air flow between the air inlet and the air outlet.

Abstract: An assembly includes a first conductor, a tube extending along the first conductor between first and second ends of the first conductor, and an electrically-insulating barrier surrounding the first conductor and the tube such that the tube is spaced from the first conductor. Another assembly includes a plurality of conductors, a first tube extending along at least one of the conductors, and an electrically-insulating barrier enclosing the conductors and the first tube in which the barrier maintains spacing between the first tube and one or more adjacent conductors. In each assembly, the tube is configured to permit a fluid to flow therethrough. A method of manufacturing a feeder cable includes providing conductors that extend between first and second lugs of each conductor, enclosing the conductors within an electrically-insulating layer, and forming a cooling passage within the electrically-insulating layer that extends along one of the conductors.

Abstract: A contactor arrangement includes a post, a fastener and a temperature sensor. The post defines a post axis. The fastener is fixed to the post along the post axis. The temperature sensor is in thermal communication with the contactor conductor and post through the fastener and is electrically insulated from the post for monitoring resistive heat generation in a contactor fixed to the post by the fastener.

Abstract: A contactor assembly post is provided. The contactor assembly post includes a first portion electrically connected to an external bus bar at an exterior of an electrical contactor housing, a second portion electrically connected to an internal bus bar at the exterior of the electrical contactor housing, a third portion and fins. The internal bus bar is configured to extend into an interior of the electrical contactor housing to be electrically coupled to another internal bus bar. The third portion extends transversely between the first and second portions. The fins extend transversely from multiple points defined along a longitudinal axis of the third portion.

Abstract: An aircraft power distribution system according to an exemplary aspect of the present disclosure includes, among other things, a power source, a load, and a power distribution panel receiving power from the power source and selectively providing power to the load. The power distribution panel includes a contactor having a housing. A heat sink provides a portion of the housing.

Abstract: A stator of an electrical generator includes a stator core including a plurality of stacked stator laminations and at least one end turn. At least one cooling passage provides a fluid flow path through a portion of the plurality of stator laminations to the at least one end turn. The at least one cooling passage includes at least one radial channel arranged in fluid communication with an axial channel. The at least one cooling passage is formed directly into the portion of the plurality of stator laminations.

Abstract: An electrical contactor assembly is provided including: an electrical contactor; an electrical bus bar; a panel; at least one post protruding through the panel and in contact with the electrical bus bar, the post being constructed from an electrically and thermally conductive material, wherein a first end of the at least one post is configured to electrically and thermally connect to the electrical contactor; and a liquid cooled heat sink thermally connected to a second end of the at least one post through the electrical bus bar, wherein the liquid cooled heat sink in operation circulates liquid coolant through the liquid cooled heat sink to absorb heat.

Abstract: An electrical interconnect arrangement for coupling a contactor with a bus bar includes a post, a bus bar connected electrically to the post, and a joint coupling the bus bar to the post. The joint has two or more interfaces defined between the post and the bus bar to reduce resistive heat generation within the electrical interconnect arrangement.

Abstract: A contactor arrangement includes a post, a fastener and a temperature sensor. The post defines a post axis. The fastener is fixed to the post along the post axis. The temperature sensor is in thermal communication with the contactor conductor and post through the fastener and is electrically insulated from the post for monitoring resistive heat generation in a contactor fixed to the post by the fastener.

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 friction stir welded component includes a channel body having a main surface and an elongated channel formed in the main surface. The elongated channel has a first depth portion that is longitudinally spanned by shoulders having a second depth, the second depth being shallower than the first depth. The body further has an abutting face that connects the main surface with one of the shoulders at an oblique angle relative to the main surface. A channel cover with an abutting face is seated against the abutting face of the channel body. A friction stir weld joint joins the channel cover to the channel body, wherein the friction stir weld joint is defined along abutting faces of the channel body and channel cover.

Abstract: Potted electronic assemblies are disclosed along with methods of making and cooling them. The electronic assemblies include a conductive heat transfer medium disposed between and in contact with an electronic component and a heat sink. The conductive heat transfer medium has a hardened fluid polymer material that includes boron nitride nanotubes dispersed therein.

Abstract: A resistance-limited electrical interface includes a printed wiring board, a bus bar, a U-shaped conductor, and a retainer. The bus bar extends from the printed wiring board. The U-shaped conductor has a first wall and an opposed second wall, the bus bar arranged between the first and second wall to define a conductive joint between the first wall and the bus bar. The retainer is compressively seated between the second wall and bus bar opposite the conductive joint to exert force on the bus bar for retaining the bus bar in the U-shaped conductor and limiting electrical resistance of the conductive joint.

Abstract: A resistance-limited electrical interface includes a printed wiring board, a bus bar, a U-shaped conductor, and a retainer. The bus bar extends from the printed wiring board. The U-shaped conductor has a first wall and an opposed second wall, the bus bar arranged between the first and second wall to define a conductive joint between the first wall and the bus bar. The retainer is compressively seated between the second wall and bus bar opposite the conductive joint to exert force on the bus bar for retaining the bus bar in the U-shaped conductor and limiting electrical resistance of the conductive joint.

Abstract: A heat pipe system includes one or more arcuate heat pipe segments shaped conforming to an inner wall of an engine rotor. The heat pipe system also includes a heat pipe fluid within the one or more arcuate heat pipe segments.

Abstract: An inductor includes a printed wiring board (PWB) and a plurality of electrically-conductive heat pipes operatively connected to the PWB. The PWB includes electrically conductive traces electrically connected to the plurality of electrically-conductive heat pipes. The traces and plurality of electrically conductive heat pipes form an inductor winding. A method of manufacturing an inductor includes mounting a plurality of electrically conductive heat pipes to a printed wiring board (PWB), wherein the PWB includes electrically conductive traces to connect the plurality of electrically-conductive heat pipes to form an inductor winding.

Abstract: An electrical contactor assembly includes an electrical contactor having an electrical lead having a contactor pin extending therefrom, an electrical bus bar, and at least one post extending between the electrical contactor and the electrical bus bar. The post is constructed from an electrically and thermally conductive material. The post includes an opening for receiving the contactor pin and the opening includes a contactor-foil material disposed in contact with the pin.

Abstract: An electrical contactor assembly is provided including: an electrical contactor; an electrical bus bar; a panel; at least one post protruding through the panel and in contact with the electrical bus bar, the post being constructed from an electrically and thermally conductive material, wherein a first end of the at least one post is configured to electrically and thermally connect to the electrical contactor; and a liquid cooled heat sink thermally connected to a second end of the at least one post through the electrical bus bar, wherein the liquid cooled heat sink in operation circulates liquid coolant through the liquid cooled heat sink to absorb heat.