Patent Publication Number: US-10763613-B2

Title: Barrier device for an electrical connector

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 62/579,260, titled “A Barrier Device for an Electrical Connector,” filed Oct. 31, 2017, which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates generally to connector assemblies, and more particularly, to a barrier device that is configured to provide a thermal protection barrier for an electrical connector. 
     BACKGROUND OF THE DISCLOSURE 
     High powered electronic devices are particularly susceptible to performance variations due to the thermal sensitivity of certain components that operate within the devices. For example, increased temperatures or extreme operating environments can lead to component failures or improper sensor readings. As such, there is a need in the art for a cost efficient and robust device that address the above concerns. 
     SUMMARY OF THE DISCLOSURE 
     According to an aspect of the present disclosure, a barrier device for an electrical connector is disclosed. In embodiments, the barrier device can comprise a first barrier element interposedly arranged between a substrate and a base assembly of the electrical connector. A second barrier element arranged for mating engagement with an upper surface of the substrate of the electrical connector; the second barrier element comprising a plurality of openings defined by a plurality of protruding structures that are configured and arranged to accommodate electronic components mounted to the upper surface of the substrate. The barrier device is designed such that the collective arrangement and positioning of the first barrier element and the second barrier element relative to substrate forms a thermal protection barrier and damping mechanism around the substrate. 
     Other features and aspects will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The detailed description of the drawings refers to the accompanying figures in which: 
         FIG. 1A  is a exploded perspective view of an interconnection device according to an embodiment; 
         FIG. 1B  is a top perspective view of the interconnection device of  FIG. 1A  according to an embodiment; 
         FIG. 2A  is a schematic diagram of an control system for controlling the interconnection device of  FIG. 1A  according to an embodiment; 
         FIG. 2B  is a schematic diagram of an inverter circuit arranged on the interconnection device of  FIG. 1A  according to an embodiment; 
         FIG. 3  is a block diagram of a motor control circuit arranged on the interconnection device of  FIG. 1A  according to an embodiment; 
         FIG. 4  is an exploded perspective view of an interconnection device according to an embodiment; 
         FIG. 5A  is an illustration of a planter unit in which the interconnection device of  FIGS. 1A and 4  may be incorporated; 
         FIG. 5B  is an illustration of the interconnection device of  FIG. 1A  coupled to a metering unit arranged in the planter unit of  FIG. 5A  according to an embodiment; and 
         FIG. 5C  is an illustration of the interconnection device of  FIG. 1  coupled to a metering unit and a brush belt assembly arranged in the planter unit of  FIG. 5A  according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring to  FIGS. 1A and 1B , an interconnection device (i.e., an electrical connector)  100  for providing an electrical connection between a motor and an inverter is shown according to an embodiment. In embodiments, the interconnection device  100  can comprise a base assembly  102 , a substrate  104  having integrated electronic circuitry  152  arranged thereon, and a cover apparatus  108  each modularly arranged relative to one another for coupling to a motor  190 . As shown in  FIG. 1B , each of the various components of the interconnection device  100  (e.g., the base assembly  102 , the substrate  104 , and the cover apparatus  108 ) can be collectively secured to the motor  190  via fasteners  180  and  182 . 
     In some embodiments, the base assembly  102  can comprise a body member  120  having a geometrical configuration that is sized and dimensioned for mating engagement with a mounting surface  196  of the motor  190  (e.g., an AC synchronous electric machine). The body member  120  can comprise a first receiving aperture  122  arranged in offset relation to a second receiving aperture  124 . The first receiving aperture  122  can be centrally arranged within the base assembly  102  and can be sized to receive a portion of a shaft  194  of the motor  190 . For example, the shaft  194  can be coaxially oriented within the first receiving aperture  122  and arranged to extend partially there through. In some embodiments, the second receiving aperture  124  can comprise a single aperture or a group of apertures such as apertures  124   a ,  124   b ,  124   c , which are sized to accommodate a plurality of motor pin connectors  192  arranged on the motor  190 . 
     A top surface  125  of the base assembly  102  can comprise a recessed channel  126  formed in or on the top surface  125  proximate an outer periphery of the body member  120  to allow for secure placement and positioning of the substrate  104 . For example, the substrate  104  can be interposedly arranged between the base assembly  102  and the cover apparatus  108 , and can be sized for fitted insertion into the recessed channel  126  formed within the base assembly  102 . 
     The substrate  104 , which can comprise, e.g., a printed circuit board or a silicon substrate, can be composed of an insulating material and can comprise a first surface  146  and a second surface  148  each arranged to face opposing directions of the interconnection device  100 . In some embodiments, a plurality of conductive traces  150  can be etched or deposited on each of the first surface  146  and the second surface  148  to provide electrical connections between electronic components of the integrated electronic circuitry  152 . For example, the integrated electronic circuitry  152  can comprise a variety of semiconductor devices, power and signal connectors, integrated circuits, and other electrical components electrically coupled to the conductive traces  150  arranged on the substrate  104 . A variety of joining techniques, such as soldering, wire bonding, adhesive bonding, flip chip bonding, bumping, tape automated bonding, or other suitable techniques can be used to the mount the various components to the conductive traces  150 . As will be discussed in further detail with reference to  FIG. 2A , in some embodiments, the integrated electronic circuitry  152  can comprise power circuits, an inverter circuits, as well as other suitable circuit components that are arranged to receive and transmit power and signal connections via one or more connector assemblies. 
     As shown in  FIG. 1B , the one or more connector assemblies can comprise a first connector assembly  142  and a second connector assembly  144 , each comprising a plurality of connection elements  143 ,  145 , can be arranged to project outwardly and away from the second surface  148 . Each of the plurality of connection elements  143 ,  145  can be adjacently arranged in spaced relation to one another. In some embodiments, the connection elements  143  of the first connector assembly  142  can be arranged to transmit and receive power and communication signals to and from external devices such as a vehicle electronics unit  350  ( FIG. 3 ) arranged on an agricultural vehicle that is arranged to tow an agricultural implement such as planter unit  500  ( FIG. 5 ). For example, the connection elements  143  can be configured to receive a DC input power source that is inverted to an AC output for supply to the motor  190 . Additionally, control commands and feedback signals can be transmitted to and from the motor  190  and the integrated electronic circuitry  152  (e.g., inverter, sensors, energy storage devices, microprocessors, etc.) via the connection elements  143 . 
     The connection elements  145  of the second connector assembly  144  are oriented to be in respective alignment with apertures  124   a ,  124   b ,  124   c  of the second receiving aperture  124  arranged on the base assembly  102 . Each of the connection elements  145  can comprise a cylindrical body having inner annular surfaces defining conductive channels (not shown) that are sized to precisely receive the motor pin connectors  192 . For example, the connection elements  145  can be sized and dimensioned to ensure sufficient electrical contact is maintained between connection elements  145  and the motor pin connectors  192 . Each connection element  143  is configured to supply a specific phase connection of, e.g., a three-phase power supply to the motor  190 , wherein each connection element  145  can be interchangedly designated (i.e., signal terminal, supply terminal, ground terminal) according to design and/or specification requirements. Although in embodiments herein, a three-phase connector assembly is shown, it should be noted that, in other embodiments, fewer or more phase connections can be used. 
     The cover apparatus  108  can be sized to enclose the substrate  104  and the base assembly  102 . In embodiments, the cover apparatus  108  can comprise an enclosure  160  having one or more coupling mechanisms  162  arranged along an outer edge of the enclosure  160  for attaching the cover apparatus  108  to the motor  190 . In some embodiments, the cover apparatus  108  can further comprise a heat dissipating element which helps to facilitate removal of excess heat generated by the motor  190  and integrated electronic circuitry  152  arranged on substrate  104  (i.e., provides a path for heat transfer). A connector support  164  can be mounted to an outer surface of the cover apparatus  108  and can comprise a plurality of connector walls  165  that are arranged to define an inner open space for receiving and enclosing the connection elements  143 . 
     As will be appreciated by those skilled in the art,  FIG. 1  is provided merely for illustrative and exemplary purposes and is in no way intended to limit the present disclosure or its applications. In other embodiments, the arrangement and/or structural configuration of interconnection device  100  can and will vary. For example, as will be discussed with reference to  FIG. 4 , in other embodiments, the interconnection device  100  can further comprise additional structure to provide thermal and/or water ingress protection. In some embodiments, additional sensor components such as temperature or motor sensors can be mounted locally on either surface of the substrate  104 . Further, the interconnection device  100  is scalable in size and performance (i.e., component sizing and power density can be increased or decreased) based on application and/or specification requirements. 
     Referring to  FIGS. 2A-2B , a control system  200  for controlling the motor  190  is shown according to an embodiment. In embodiments, the control system  200  can comprise a power circuit  220 , which may include a DC power source, coupled to an inverter circuit  202 , a motor control circuit  206 , a driver circuit, and an overprotection circuit  208 . In some embodiments, the control system  200  can optionally comprise a filtering circuit  214  electrically coupled between the power circuit  220  and the inverter circuit  202 . The filtering circuit  214  can comprise smoothing capacitors, RC filters, or other suitable filtering components in various embodiments that operate to reduce unwanted noise and ripples in the DC power source generated by the power circuit  220 . 
     In some embodiments, the inverter circuit  202  can comprise a switching circuit  230  arranged in parallel with a power source  240  (e.g., a DC power source) and operates to convert the DC input power to an AC output power for use by the motor  190 . The switching circuit  230  can comprise a plurality of switching units (e.g., a first switching unit  232 , a second switching unit  234 , a third switching unit  236 ) each having one or more switching elements  232   a ,  232   b ,  234   a ,  234   b ,  236   a ,  236   b  arranged to generate the three-phase AC output power  250 . In embodiments, the one or more switching elements  232   a ,  232   b ,  234   a ,  234   b ,  236   a ,  236   b  can comprise insulated gate bipolar transistors (IGBT), metal-oxide Field-Effect Transistors (MOSFET), Silicon Carbide MOSFETs, Silicon Carbide IGBTs, static induction transistors (SITs), combinations thereof, or other suitable switching devices. 
     As depicted in  FIG. 2B , the first switching unit  232  comprises a first switching element  232   a  coupled in series with a second switching element  232   b  between the power source  240  and ground. A first phase output (e.g., U-phase) is supplied to an input terminal (e.g., motor pin connector  192   a ) of the motor  190  via the connection elements  145  arranged in the second connector assembly  144 . 
     Similarly, the second switching unit  234  and the third switching unit  236 , which include switching elements  234   a ,  234   b ,  236   a ,  236   b  arranged in series between the power source  240  and ground, are configured to provide the second and third phase outputs (e.g., V-phase and W-phase) to the corresponding input terminals (e.g., motor pin connectors  192   b ,  192   c ) of the motor  190  via the connection elements  145  arranged in the second connector assembly  144 . Driver signals are applied to an input of each of the switching units  232 ,  234 ,  236  from the driver circuit  204 . For example, the driver circuit  204  is configured to independently activate and deactivate each of the switching elements  232   a ,  232   b ,  234   a ,  234   b ,  236   a ,  236   b  in response to control signals received from the motor control circuit  206 , or in response to overcurrent signals received from the overprotection circuit  208 . 
     In some embodiments, the motor control circuit  206  can comprise an electronic data processor and other electronic circuitry as will be discussed in further detail with reference to  FIG. 3 . The motor control circuit  206  is arranged to receive input signals from the overprotection circuit  208  and the motor sensor  210 , and is configured to compute and output position, speed, and torque commands to the driver circuit  204  for the control of the motor  190  based on the received signals. The overprotection circuit  208  can be coupled to a current sensor  212  that is configured to detect current applied to the motor windings and/or back electromotive force (EMF). In some embodiments, the overprotection circuit  208  can be configured to compare the detected current values received from the current sensor  212  to a predetermined threshold valve and generate a corresponding output signal to the driver circuit  204 . For example, if an overcurrent condition is detected (i.e., the current value exceeds the threshold value), the overprotection will generate an output signal that interrupts the operation of the inverter circuit  202  via the driver circuit  204 . 
     In some embodiments, a motor sensor  210  (see  FIG. 4 ) can be centrally arranged on the second surface  448  of the substrate  404  in coaxial alignment with the shaft  194 . In some embodiments, the motor sensor  210  can comprise a position sensor, resolver, or encoder that is associated with the shaft  194  or the rotor. The motor sensor  210  can be coupled to the motor control circuit  206  to provide feedback data (e.g., current feedback data, such as phase current values i u , i v  and i w ), raw position signals, among other possible feedback data or signals, for example. Other possible feedback data includes, but is not limited to, winding temperature readings, semiconductor temperature readings of the inverter circuit  202 , three phase voltage data, or other thermal or performance information for the motor  190 . 
     In other embodiments, the motor sensor  210  can comprise a speed sensor that is configured to estimate at least one of an angular position of the shaft  194 , a speed or velocity of the shaft  194 , and a direction of rotation of the shaft  194 . In some embodiments, the motor sensor  210  may be coupled to an analog-to-digital converter (not shown) that converts analog raw position data or velocity data to digital raw position or velocity data, respectively. 
     Referring to  FIG. 3 , a block diagram of the motor control circuit  206  is shown according to an embodiment. In embodiments, the motor control circuit  206  can comprise an electronic data processor  320 , memory  322 , an input/output module  324  communicatively coupled to a data bus  326 , which support communications of data between or among the electronic data processor  320 , memory  322  and an input/output module  324 . 
     The electronic data processor  320  can comprise a microprocessor, a microcontroller, a programmable logic array, a logic circuit, an arithmetic logic unit, an application specific integrated circuit, a digital signal processor, a proportional-integral-derivative (PID) controller, or another data processing device. 
     The memory  322  can comprise any magnetic, electronic, or optical device for storing data (e.g., position data, sensor data, current data, voltage data, etc.) and software instructions that are executed by the electronic data processor  320 . The electronic data processor  320  controls the operations of the control system  200  based on the executed instructions. For example, in response to the executed instructions, the electronic data processor  320  generates control signals that control the switching elements  232   a ,  232   b ,  234   a ,  234   b ,  236   a ,  236   b  arranged in the inverter circuit  202  to drive the motor  190 . In various embodiments, the memory  322  can comprise an electronic data storage device, an electronic memory, non-volatile electronic random access memory, one or more electronic data registers, data latches, a magnetic disc drive, a hard disc drive, an optical disc drive, or the like. 
     The input/output module  324  provides an interface between various input and output devices (e.g., driver circuit  204 , switching elements  232   a ,  232   b ,  234   a ,  234   b ,  236   a ,  236   b , sensors  210 ,  212 ). In embodiments, the input/output module  324  can comprise a plurality of data interfaces. Each data interface can comprise a transceiver and buffer memory, for example. In some embodiments, each data interface can include any serial or parallel input/output port. Additionally, in some embodiments, the input/output module  324  can further comprise an analog to digital converter (not shown) that is configured to convert the phase current values of the motor  190  to digital values for transfer to the electronic data processor  320  via the data bus  326 . 
     In other embodiments, the vehicle electronics unit  350  can be configured to transmit speed and or torque commands to the motor control circuit  206  through the input/output module  324  and the data bus  326 . For example, the vehicle electronics unit  350  may provide data messages such as speed or torque commands via the input/output module  324 . Such commands may also be generated by a vehicle operator via a user interface, such as, e.g., a throttle, a pedal, a controller, or other suitable input devices. 
     Referring now to  FIG. 4 , an interconnection device  400  is shown according to an embodiment. The interconnection device  400  is substantially similar to interconnection device  100 , therefore like reference numerals will be used to designate similar features and such features will not be discussed in detail. In embodiments, the interconnection device  400  can further comprise a thermal protection barrier (i.e., a barrier device)  406  having a first isolation element  405  and a second isolation element  407  arranged on opposing sides of the substrate  404 . Such an arrangement is particularly advantageous in that it not only provides a thermal isolation barrier between the motor  190 , but it also prevents thermal crosstalk of the motor  190  and the integrated electronic circuitry  452  arranged on substrate  404 . It should be further noted that the collective and relative arrangement of the first isolation  405  and the second isolation element  407  with respect to the substrate  404  provides vibrational damping. This, in turn, helps to increase device reliability, device performance, sensing accuracy, and product lifetime. 
     As depicted, the first isolation element  405  can be arranged to provide a first protective barrier between the substrate  404  and the base assembly  402 . In some embodiments, the first isolation element  405  can comprise an upper portion  415  integrally formed with a lower portion  417 . The upper portion  415  can comprise a planar surface  413  having a plurality of connector apertures  423  and at least one shaft aperture  421  formed therein that are similarly arranged as a first receiving apertures  422  and a second receiving apertures  424  of the base assembly  402 . For example, the plurality of connector apertures  423  and the at least one shaft aperture  421  can be coaxially aligned with the first receiving apertures  422  and the second receiving apertures  424  arranged on the base assembly  402 . Additionally, in some embodiments, similar to the first and second receiving apertures  422 ,  424 , the plurality of connector apertures  423  and the at least one shaft aperture  421  can be arranged in offset relation to one another. The lower portion  417  can comprise an outer wall structure  425  defined by wall members  427  that is sized generally smaller than an outer circumference of the upper portion  415  such that a periphery edge of the lower portion  417  is inwardly offset from a periphery edge of the upper portion  415  as shown in  FIG. 4 . In some embodiments, the first isolation element  405  can comprise a ventilation element  437 , for example, an air vent such as a Gore-Tex vent, which allows the interconnection device to be vented to atmosphere and also allows for the interconnection device to be tested and for sufficient creepage and clearance distances to be maintained. 
     In some embodiments, the interconnection device  400  can further comprise a sealant member  435  (e.g., an O-ring) that can be arranged to form an air tight seal between the base assembly  402  and the mounting surface  196  of the motor  190  to provide water ingress protection while also simultaneously providing damping of unwanted vibrations. 
     The second isolation element  407  can be arranged to provide a second protective barrier between the substrate  404  and the cover apparatus  408 . In some embodiments, the second isolation element  407  will have a plurality of openings  445  that are defined by raised structures, which are sized to receive and accommodate the connection elements  443  and the various electronic components of the integrated electronic circuitry  452  arranged on substrate  404 . In various embodiments, each of the first isolation element  405  and the second isolation element  407  can comprise an insulating material (e.g., dielectric material). 
     Referring to  FIGS. 5A-5C , the interconnection device  100  or  400  coupled to the motor  190  is shown in use with the planter unit  500 . Although the interconnection device  100  or  400  is depicted as being incorporated into planter unit  500 , it should be noted that, in other embodiments, the interconnection device  100  or  400  may be incorporated into other agricultural applications, such as air seeding, chemical metering, and others. In embodiments, the planter unit  500  can comprise a hopper  520  arranged in a generally upright position and mounted to a first frame  522 . A metering unit  524  having a generally circular configuration can be arranged beneath hopper  520  and can be configured to distribute seeds received from hopper  520  into a seed tube  526 . For example, the metering unit  524  can be configured to singulate seed received from the hopper  520  for delivery to the seed tube  526 . The seed tube  526  directs the seeds received from the metering unit  524  to a soil opening  540  formed in the soil  550  by a ground engaging device  530 . In some embodiments, ground engaging device  530  can comprise at least one opener disc  532  that is rotatable about a center axle and arranged to form the soil opening  540 , whereas, in other embodiments, two or more opener discs may be utilized according to design and/or specification requirements. 
     An extension bar  531  may be configured to operate (i.e., lower and raise) collectively with a height adjusting arm  528 , the operation of which is controlled by a user such as a vehicle operator. The height adjusting arm  528  can be operably coupled to at least two gauge wheels  534  mounted proximate the ground engaging device  530  and may be configured to regulate the penetration depth of ground engaging device  530  via the height adjusting arm  528 . For example, the height adjusting arm  528  enables the vertical position of the gauge wheels  534  to be adjusted relative to the ground engaging device  530 , which establishes the depth at which the ground engaging device  530  is inserted into the soil  550  (i.e., the depth of the soil opening). To vertically adjust the gauge wheels  534 , the height adjusting arm  528  having a lower bearing surface  529  engages against at least one of the gauge wheels  534  and is secured to a second frame  533  by a bracket  527 . 
     A closing wheel assembly  536  can be arranged following of the gauge wheels  534  and is operable to close the soil opening  540  formed by ground engaging device  530 . In some embodiments, planter unit  500  may further comprise a location-determining receiver  545 , such as a satellite navigation receiver, that is mounted to the planter unit  500  and configured to provide field location data. 
     In  FIG. 5B , an alternative hopper and metering unit arrangement is shown. As depicted in  FIG. 5B , a hopper  620 , which can include a mini hopper, is mounted to the side of a metering unit  624 . The metering unit  624  can be driven by a control device  625 , which can include the motor  190  having either the interconnection device  100  or  400  mounted thereto, that is mounted to the hopper  620  via a bracket  622 . In some embodiments, the motor  190  of the control device  625  can be connected to a drive input  630  of a gearbox  632 . Such an arrangement provides a control interface directly to the metering unit  624 . For example, use of dedicated control devices  625  enables the speed of each metering unit to be adjusted as the path of the planter changes to maintain the desired seed spacing for each row of the planter. 
     In other embodiments, the planter unit  500  can further comprise a delivery system  640  that is associated with the metering unit  624 . The delivery system  640  can comprise a housing  642  having a brush belt assembly (not shown) mounted thereto. At least one second control device  627  can be coupled to the delivery system  640  as shown in  FIG. 5C . A mounting bracket  645  that is coupled to a row unit frame such as the frame  522  can be arranged to support the metering unit  624 , the delivery system  640 , and the one or more control devices  627 . As depicted, in operation, the metering unit  624  and the delivery system  640  are adapted to move through a field in the direction indicated by the arrow  647 . 
     As previously discussed with reference to  FIGS. 2A and 3 , in operation, the control device  625  can be automatically controlled via the control system  200  arranged on the interconnection device  100 . For example, data commands can be sent to each individual control device  625  via a vehicle electronics unit or based an input received via an operator interface, which can be arranged in a cab of an agricultural vehicle. Additionally, in some embodiments, alarm and alert signals can be generated for display on the operator interface based on feedback signals generated by the overprotection circuit  208  and/or the motor sensor  210 . 
     Without in any way limiting the scope, interpretation, or application of the claims appearing below, a technical effect of one or more of the example embodiments disclosed herein is a barrier device for an electrical connector. The present disclosure overcomes the limitations of the prior art by providing a thermal isolation barrier, as well as thermal crosstalk reduction to optimize signal performance. Additionally, the barrier device provides for a simplistic design and scalable architecture that is cost efficient and which can be optimally adapted for a wide variety of applications and power requirements. 
     While the above describes example embodiments of the present disclosure, these descriptions should not be viewed in a limiting sense. Rather, other variations and modifications may be made without departing from the scope and spirit of the present disclosure as defined in the appended claims.