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: 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: 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 cold plate assembly is provided having a base defining a cooling channel and a heat exchanger friction-stir welded to the base, wherein the heat exchanger is located within a portion of the cooling channel, and the friction-stir welding between the heat exchanger and the base forms a fluid seal.

Abstract: A fluid cooled cold plate includes a main coolant passage with a first cross-sectional area taken laterally in a direction perpendicular to the flow direction and a finned coolant passage having a second cross-sectional area taken laterally in a direction perpendicular to the flow direction, with the second area smaller than the first area. Fluidly connecting the main coolant passage with the finned coolant passage is a branch oriented such that a fluid is turned 90° or more when passing into the branch from the main coolant passage. Also included is a coolant bypass passage in fluid communication with the main coolant passage and located fluidically parallel to the finned coolant passage.

Abstract: A system for cooling an electronics box includes an electronics box with a first portion and a second portion. During a low load condition on the electronics box the first portion and the second portion require a substantially similar amount of cooling air and during a high load condition on the electronics box the second portion requires a substantially greater amount of cooling air than the first portion. The system further includes a first plenum in fluid communication with the first portion and a second plenum in fluid communication with the second portion. A normal cooling air supply is in fluid communication with both the first plenum and the second plenum during the low load condition on the electronics box, and a supplemental cooling air supply in fluid communication with the second plenum during the high load condition on the electronics box.

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: An electrical connector interface comprises a plug connector assembly, a receptacle connector assembly, and an anti-rotation fastener receiving post. A plurality of spaced apart conductive contact sockets each have a mating end retained in a monolithic mating portion of a nonconductive plug connector shell body. A plurality of spaced apart conductive contact pins extend into a mating portion of a nonconductive receptacle connector shell body. The nonconductive plug and receptacle connector shell bodies each have an external mounting flange with a anti-rotation aperture. The anti-rotation fastener post has a first anti-rotation end insertable into either the plug anti-rotation aperture or the receptacle anti-rotation aperture.

Abstract: An AC-AC power converter supplies AC power to an AC motor having a plurality of motor windings and a case connected to a ground. The AC-AC power converter architecture includes an asymmetric phase shift autotransformer/rectifier unit (ATRU) that converts an AC input to a DC output, wherein the asymmetric phase shift ATRU generates a common-mode AC voltage across the asymmetric phase shift ATRU. The common mode voltage is diverted to ground through motor case parasitic capacitance via a common-mode voltage pull-down circuit connected between each phase of the ATRU AC input and the ground.

Abstract: A transformer assembly comprises a magnetic core assembly, a bobbin assembly, a coil winding, a transformer interconnect trace, and a coil winding terminal post. The bobbin assembly includes a coil winding assembly disposed around a portion of the magnetic core assembly. The transformer interconnect trace is fixed to a substrate secured to the transformer assembly proximate the bobbin assembly. The coil winding terminal post receives a coil winding end for electrically connecting the coil winding end to the transformer interconnect trace through the coil winding terminal post.

Abstract: An electrical connector interface comprises a plug connector assembly, a receptacle connector assembly, and an anti-rotation fastener receiving post. A plurality of spaced apart conductive contact sockets each have a mating end retained in a monolithic mating portion of a nonconductive plug connector shell body. A plurality of spaced apart conductive contact pins extend into a mating portion of a nonconductive receptacle connector shell body. The nonconductive plug and receptacle connector shell bodies each have an external mounting flange with a anti-rotation aperture. The anti-rotation fastener post has a first anti-rotation end insertable into either the plug anti-rotation aperture or the receptacle anti-rotation aperture.

Abstract: An electronics cooling system comprises a tubular fan duct and an electronics housing. The fan duct includes has a fan duct casing containing a fan with rotor blades and stator vanes. The electronics housing is mounted directly on the tubular fan duct, such that the electronics housing and the fan duct casing together enclose an interior space. A cooling airflow path extends from a high-pressure region of the tubular fan duct, through an inlet hole into the interior space, and out a bleed hole into a surrounding environment. The electronics cooling system further comprises three electronics mounts within the interior space. A first electronics mount is located immediately adjacent to the inlet hole, on the fan duct. A second electronics mount is located immediately radially outward of the stator vanes, on the fan duct. A third electronics mount is located immediately adjacent to the bleed hole, on the housing.

Abstract: An AC-AC power converter supplies AC power to an AC motor having a plurality of motor windings and a case connected to a ground. The AC-AC power converter architecture includes an asymmetric phase shift autotransformer/rectifier unit (ATRU) that converts an AC input to a DC output, wherein the asymmetric phase shift ATRU generates a common-mode AC voltage across the asymmetric phase shift ATRU. The common mode voltage is diverted to ground through motor case parasitic capacitance via a common-mode voltage pull-down circuit connected between each phase of the ATRU AC input and the ground.

Abstract: A cooling system for a transformer comprises a fan duct and a housing which together enclose an interior space. A transformer located in the interior space is mounted on the fan duct, and has a plurality of core sections surrounded by windings and separated by gaps. An air channeling structure is located between the transformer and the fan duct. A cooling airflow path extends through the air channeling structure, and between core sections of the transformer.

Abstract: A feed-through capacitor is constructed in a printed wiring board using alternating layers of metal capacitive layers and plastic dielectric layers of the printed wiring board. The large number of layers, the avoidance of ceramic layers and the flexible geometry of this device allow it to be used in many applications, particularly in those involving high power high current. Also, because it utilizes a printed wiring board, the capacitor can be made in numerous sizes and shapes.

Abstract: An electronics cooling system comprises a tubular fan duct and an electronics housing. The fan duct includes has a fan duct casing containing a fan with rotor blades and stator vanes. The electronics housing is mounted directly on the tubular fan duct, such that the electronics housing and the fan duct casing together enclose an interior space. A cooling airflow path extends from a high-pressure region of the tubular fan duct, through an inlet hole into the interior space, and out a bleed hole into a surrounding environment. The electronics cooling system further comprises three electronics mounts within the interior space. A first electronics mount is located immediately adjacent to the inlet hole, on the fan duct. A second electronics mount is located immediately radially outward of the stator vanes, on the fan duct. A third electronics mount is located immediately adjacent to the bleed hole, on the housing.

Abstract: A cooling system for a transformer comprises a fan duct and a housing which together enclose an interior space. A transformer located in the interior space is mounted on the fan duct, and has a plurality of core sections surrounded by windings and separated by gaps. An air channeling structure is located between the transformer and the fan duct. A cooling airflow path extends through the air channeling structure, and between core sections of the transformer.

Abstract: A feed-through capacitor is constructed in a printed wiring board using alternating layers of metal capacitive layers and plastic dielectric layers of the printed wiring board. The large number of layers, the avoidance of ceramic layers and the flexible geometry of this device allow it to be used in many applications, particularly in those involving high power high current. Also, because it utilizes a printed wiring board, the capacitor can be made in numerous sizes and shapes.

Abstract: An apparatus, and a method of opening and closing electrical power feed lines using a hybrid contactor, which combines a traditional set of mechanical main contacts with a high voltage solid state switch. The solid state switch provides a parallel current path around the main contacts. When the main contacts are to be opened or closed, the solid state switch is first closed, diverting current away from the main contacts to prevent arc formation when the main contacts are being opened or closed. Once the main contacts are opened or closed, the solid state switch is opened, as the parallel current path is no longer needed. Optional auxiliary contacts are connected in series with the solid state switch to provide galvanic isolation between an input terminal and an output terminal.

Abstract: An apparatus, and a method of opening and closing electrical power feed lines using a hybrid contactor, which combines a traditional set of mechanical main contacts with a high voltage solid state switch. The solid state switch provides a parallel current path around the main contacts. When the main contacts are to be opened or closed, the solid state switch is first closed, diverting current away from the main contacts to prevent arc formation when the main contacts are being opened or closed. Once the main contacts are opened or closed, the solid state switch is opened, as the parallel current path is no longer needed. Optional auxiliary contacts are connected in series with the solid state switch to provide galvanic isolation between an input terminal and an output terminal.