Claims:I/We Claim:

1. An electronic assembly (201) comprising:
a plurality of electronic components (202) mounted on at least one base member (208, 209);
at least one terminal block (206) mounted on the at least one base member (208, 209), wherein a plurality of electrical terminals (203a, 203b, 203c, 203d, 203d, 203e, 203f) extends from the at least one terminal block (206); and
a support assembly (207) mounted on a top surface of the at least one terminal block (206) for distributing load experienced by the plurality of electrical terminals (203a, 203b, 203c, 203d, 203d, 203e, 203f) to at least one packaging member (210, 211).
2. The electronic assembly (201) as claimed in claim 1, wherein the support assembly (207) comprises:
a flat metallic support member (215), with a plurality of primary apertures (301), connected to the at least one packaging member (210, 211),
an external insulating sleeve (216), with a plurality of secondary apertures (302), at least partially enclosing the support member (215);
a plurality of bush members (303) to be inserted into the plurality of primary apertures (301) and the plurality of secondary apertures (302), and
a plurality of fasteners (217) to engage with the plurality of bush members (303) for fastening the support assembly (207) to the at least one terminal block (206) at predetermined mounting locations.
3. The electronic assembly (201) as claimed in claim 2, wherein the primary apertures (301) are in-line with the secondary apertures (302).
4. The electronic assembly (201) as claimed in claim 2, wherein a pair of the fasteners out of the plurality of fasteners (217) is fastened to the at least one terminal block (206) above each of the plurality of electrical terminals (203a, 203b, 203c, 203d, 203d, 203e, 203f).
5. The electronic assembly (201) as claimed in claim 2, wherein the at least one packaging member is a pair of cooling rails (210, 211) of an electronic product (100) constituted by the electronic assembly (201).
6. The electronic assembly (201) as claimed in claim 5, wherein each of the pair of cooling rails (210, 211) is positioned proximal to longitudinal sides of the at least one base member (208, 209).
7. The electronic assembly (201) as claimed in claim 5, wherein a wing portion (215a) of the support member (215) is mounted to each of the pair of cooling rails (210, 211), wherein the wing portion (215a) extends from sides of the support member (215) and is exposed outside the sleeve (216).
8. The electronic assembly (201) as claimed in claim 5, wherein the electronic product (100) further comprises a plurality of heat transfer bridges (204) connected to the pair of cooling rails (210, 211) for cooling the at least one base member (208, 209) and the electronic components (202) mounted on the at least one base member (208, 209).
9. The electronic assembly (201) as claimed in claim 2, wherein the support member (215) is one of removably disposed within the sleeve (216) and en-moulded within the sleeve (216).
10. The electronic assembly (201) as claimed in claim 2, wherein the support member (215) and the sleeve (216) have arcuate edges (304, 305) and are similar in shape.
11. The electronic assembly (201) as claimed in claim 1, wherein the at least one terminal block (206) is positioned proximal to a lateral edge (208a) of the at least one base member (208, 209) and fastened to the at least one base member (208, 209) at a bottom surface (208c).
12. The electronic assembly (201) as claimed in claim 1, wherein the electrical terminals (203a, 203b, 203c, 203d, 203d, 203e, 203f) are connected to the plurality of electronic components (202) using bus bars (212).
, Description:TECHNICAL FIELD
[0001] The present subject matter relates to an electronic assembly. More particularly and not exclusively, it pertains to construction of the electrical terminals of the electronic assembly.

BACKGROUND
[0002] In recent years, processor-based systems and computer systems have found widespread application in any engineering domain. The processor-based systems are temperature and vibration sensitive. The processor-based systems are susceptible to vibrations during their lifetime, which may lead to functional failure and fatigue damage to it. To be deployed in rugged environments, such as, in power trains of electric vehicles and hybrid electric vehicles, efficient heat dissipation and thermal management needs to be done in the processor-based systems and it needs to be packaged in a manner that it can withstand the external shocks and vibrations. The construction of the processor-based systems is thus critical to its longevity, safety, serviceability, and maintainability and also the application in which it is employed.

BRIEF DESCRIPTION OF DRAWINGS
[0003] The detailed description is described with reference to the accompanying figures. The same numbers are used throughout the drawings to reference like features and components.
[0004] Fig. 1 exemplarily illustrates a front perspective view of an electronic product;
[0005] Figs. 2A-2D exemplarily illustrate different views of the electronic product without the casing and the end covers; and
[0006] Fig. 3 exemplarily illustrates an exploded view of the support assembly.

DETAILED DESCRIPTION OF THE INVENTION
[0007] In the following description, numerous specific details are set forth to provide a thorough understanding of the embodiments. One skilled in the relevant art will recognize, however, that the techniques described herein can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring certain aspects.
[0008] It is contemplated that the disclosure in the present invention may be applied to any vehicle without defeating the spirit of the present subject matter. The detailed explanation of the constitution of parts other than the present invention which constitutes an essential part has been omitted at suitable places.
[0009] In electric/ hybrid electric vehicles, the parts of the electric drive train, such as, one or more controllers, one or more inverters, power boards, voltage converter boards, etc., tend to get heated up and may fail to function after a certain number of use cycles causing discomfort to the rider of the vehicle, during normal usage and/or prolonged operation. Sometimes, the continuous heating up may also lead to fire propagation in the electric drive train, leading to a catastrophic failure of the electric drive train and the vehicle. Thus, there is a need to effectively dissipate the generated heat in the parts and efficiently cool the parts for good performance and longevity as well as to arrest propagation of fire, if any, for the safety of a product employing the components, such as, the vehicle.
[00010] Based on the output wattage of the electric or hybrid electric vehicle, the number, size, and technical specifications, of the parts in the vehicle, vary. Each of these parts has multiple electrical and electronic components, such as, capacitors, transistors, resistors, etc., whose specifications and ratings also vary. For a higher wattage of the electric drive train of the vehicle, the electrical and electronic components vary in quantity, in size, in ratings, and other technical specifications. With the increased sizes and numbers, the positioning of the electrical and electronic components in the various parts of the electrical drive train is difficult and needs to be performed optimally. With the increased size, density and wattage of the number of the electrical and electronic components in the part, the part or the electronic product becomes bulkier and difficult to assemble, service, and maintain in the vehicle.
[00011] In case, the casing of the electronic product experiences vibrations, it transmits the vibrations to the electronic components affecting the functionality of the electronic product in long run. Loose packaging of the electronic components can compromise cycle life of the electronic product. The vibrations may also set exothermic reactions within the electronic product resulting in release of smoke or toxic gases and high-pressure events leading to a catastrophic failure of the electronic product. A reliable packaging of the electronic product is needed for mechanical stability, durability, thermal stability, vibration isolation, and impact resistance of the electronic product.
[00012] The electrical and electronics components, such as, the ICs, transistors, capacitors, resistors, etc., are usually mounted and soldered to the PCB board. The mounting of these components on the PCB board should not make it heavy, clumsy, congested and difficult for assembly, troubleshooting, maintenance, and replacement. In conventional design, the electrical terminals of the electronic product are mounted on the PCB board. The mounting of the components tightly on the PCB board exerts a torsional stress on the PCB board. Thus, the components on the PCB exert a load on the PCB board. The electrical terminals are often connected externally to other cables that connect to another electronic product in the vehicle, such as, a battery.
[00013] For example, in a conventional design of a PCB based electronic product, such as, a low power controller, the capacity of the controller is low. However, the weight of the electronic components is also low due to the low power rating of the electronic components. The voltages handled by the PCB board are also low and thus, the cables running from the electrical terminals may also be thin and less in weight. Further, such low power controllers are only used in low powered vehicle. Additionally, the electronic components on the PCB exert pressure on the PCB board and the board itself functions as a load bearing member. However, these PCB based low power controllers cannot meet the demands of high-power applications, such as, an electric or a hybrid electric vehicle. These high-power applications require a high power rated electronic product, such as, a high power rated controller.
[00014] The high power rated controllers are bulkier and have heavier electrical and electronic components assembled on a PCB board. The PCB board bears the weight of the heavier, denser, and larger components mounted on it. The mounting of the electrical terminals too exerts a load on the PCB board. The electrical terminals are often connected with high voltage cables running towards the battery or another electronic product, such as, a motor in the electric or hybrid electric vehicle. These external cables also exert large amounts of load on the PCB board and the PCB board may give away after some operation cycles due to the vibrations the electronic product is susceptible. As the PCB fails, the electronic product may fail subsequently resulting in a catastrophe in the high-power applications. Also, assembly of such PCBs within a casing needs additional tooling and utmost care while doing it, thereby increasing man-hours in assembly, servicing, troubleshooting, and maintenance. Also, the load from the PCB board is not transferred to other structural members within the casing as the PCB board fails to be in contact with any of them.
[00015] In other conventional attempts, the PCB boards are mounted on a backing member that also functions as a heat sink. The backing member has a flat planar surface on which one or more PCB boards along with its components are mounted. In this configuration, the load of the terminals and the cables connected to the terminals is transferred from the PCB board to the backing member, thereby reducing the stress on the PCB board. However, a problem in this is that the backing member being heat sink is only in contact with the PCB board and not the electronic components over it. The heat generated by the PCB board is extracted, however, the heat generated by the components on it is still higher, leading to eventual failure of the board and the electronic board. There is a need for a common heat dissipation assembly for the multiple PCB boards and the electronic components mounted on them, within the electronic product.
[00016] To address this need, in some conventional designs of high power rated controllers, the heat dissipation assembly is in contact with the electronic components on the PCB board as well as the PCB board itself. However, the load transfer from the electrical terminals to the structural elements in the electronic product is still a problem as there is no mechanical contact between the electrical terminals and the structural elements. To establish the mechanical contact, the electronic product may require additional components, such as shock absorbers within the casing.
[00017] Existing packaging of the electronic components within a casing employs a packaging material which can withstand raised temperatures and pressures. However, the packaging material needs to be uniformly distributed along the length of the casing using a fastening means. Such packaging material increases the weight, the manufacturing cost, and the assembling cost of the electronic assembly. Also, while loading or unloading the PCB board into the casing, the packaging material may hinder the ease in pushing in or pulling out of the electronic assembly from the casing. To address this problem, the packaging material has to be made firm and rigid to not deform, while loading and unloading of the electronic assembly.
[00018] The electrical terminals usually originate from the PCB board and protrude through the end cover external of the electronic product. The torsional load on fastening the electrical terminals to the PCB board is transferred to baffle like structures in an inner surface of the end cover of the electronic product. However, the use of baffles was still not optimum to prevent damage of the PCB as the baffles usually made of plastic may fail after some prolonged use.
[00019] Therefore, there exists a need for an improved design of an electronic assembly that is durable, can sustain shocks and vibrations, with efficient and effective heat transfer from the electrical and electronic components which additionally provides ease and safety during assembly, use, maintenance, and servicing of the electronic assembly, while curtailing fire propagation and overcoming all problems disclosed above as well as other problems of known art.
[00020] In an embodiment, an electronic assembly is disclosed. The electronic assembly comprises a plurality of electronic components mounted on at least one base member, at least one terminal block mounted on the at least one base member, and a support assembly mounted on a top surface of the at least one terminal block. A plurality of electrical terminals extends from the at least one terminal block and the support assembly distributes load experienced by the plurality of electrical terminals to at least one packaging member.
[00021] In an embodiment, the support assembly comprises a flat metallic support member, with a plurality of primary apertures, an external insulating sleeve, with a plurality of secondary apertures, at least partially enclosing the support member, a plurality of bush members to be inserted into the plurality of primary apertures and the plurality of secondary apertures, and a plurality of fasteners to engage with the plurality of bush members for fastening the support assembly to the terminal block at predetermined mounting locations. In an embodiment, the primary apertures are in-line with the secondary apertures. The metallic support member is connected to the at least one packaging member.
[00022] In an embodiment, a pair of the fasteners, out of the plurality of fasteners, is fastened to the terminal block above each of the plurality of electrical terminals.
[00023] In an embodiment, the at least one packaging member is a pair of cooling rails of an electronic product constituted by the electronic assembly. Each of the pair of cooling rails is positioned proximal to longitudinal sides of the at least one base member. In an embodiment, a wing portion of the support member is mounted to each of the pair of cooling rails, wherein the wing portion extends from sides of the support member and is exposed outside the sleeve. The electronic product further comprises a plurality of heat transfer bridges connected to the pair of cooling rails for cooling the at least one base member and the electronic components mounted on the at least one base member.
[00024] In an embodiment, the support member is one of removably disposed within the sleeve and en-moulded within the sleeve. In another embodiment, the terminal block is positioned proximal to a lateral edge of the at least one base member and fastened to the at least one base member at a bottom surface.
[00025] In an embodiment, the electrical terminals are connected to the electronic components using bus bars.
[00026] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[00027] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims.
[00028] In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosure. It is to be understood that the forms of the disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.
[00029] Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense, and should in no way be construed as limiting of the present disclosure. All joinder references (e.g., attached, affixed, coupled, connected, etc.) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the systems and/or methods disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other.
[00030] Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification.
[00031] It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. Additionally, any signal hatches in the drawings/figures should be considered only as exemplary, and not limiting, unless otherwise specifically specified.
[00032] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[00033] Fig. 1 exemplarily illustrates a front perspective view of an electronic product 100. The electronic product 100 may be used in high power rated applications, such as, a part of an IC engine-based vehicle, or part of a drive train of an electric vehicle or a hybrid electric vehicle. The vehicle may be a two-wheeled vehicle, a three wheeled or a multi-wheeled vehicle, such as, a passenger car, a passenger bus, a load carrying truck, etc. The electronic product 100 may be an inverter, a controller, a power conditioning circuit, a voltage converter, etc., of the drive train of the vehicle. As exemplarily illustrated, the electronic product 100 comprises a casing 101 enclosing an electronic assembly 201 (shown in Fig. 2A) with the electrical and electronic components 202 (shown in Fig. 2A) and a pair of end covers 103, 104. The casing 101 is a hollow geometry cover with open ends enclosing the electronic assembly 201. End covers 103, 104 of the electronic product 100 close the open ends of the casing 101. In an embodiment, the end covers, such as, a first end cover 103 and a second end cover 104 and the casing 101 have mounting provisions to be fastened together at the open ends, using attachment means. The second end cover 104 has provisions 104a for the external electrical terminals 203a, 203b, 203c, 203d, 203e, 203f of the electronic product 100. The first end cover 103 seals the casing 101 on the other side. In an embodiment, an outer surface of the casing 101 may comprise a plurality of fins 102 for thermal management of the electronic product 100. In another embodiment, the outer surface of the casing 101 may comprise a dovetail pattern that facilitates in easy mounting and removal of the electronic product 100 in a designated space in an application, such as, the vehicle. In an embodiment, an inner surface of the casing 101 may comprise a dovetail pattern that facilitates in easy mounting and removal of the electronic assembly 2001 into and out of the casing 101 for accessing the mounted electrical and electronic components. In an embodiment, the inner surface of the casing 101 may comprise a groove.
[00034] Figs. 2A-2D exemplarily illustrate different views of the electronic product 100 without the casing 101 and the end covers 103, 104. The electronic product 100 comprises one or more electronic assemblies, such as, 201. An electronic assembly 201 is a congregation of multiple electrical and electronic components 202 connected to each other to achieve a defined function, such as, stepping down voltages, converting AC voltage to DC voltage, etc. The electronic assembly 201 comprises one or more base members 208, 209 for mounting multiple electronic components, such as, 202. The base members 208, 209 can be seen to positioned one below the other and fastened together. Each of the base members 208, 209 may be for a different function such as power regulation, signal conditioning, voltage conversion, voltage inversion, etc. For example, the electronic product is a motor controller connected to a motor and a battery in the vehicle. The base member 208 may be a power board of the motor controller and the base member 209 may be a control board of the motor controller. In an embodiment, the pins of the electronic components 202 are inserted into openings on the base members 208, 209 and the pins are soldered to the base members 208, 209. Each of the base members 208, 209 may be a printed circuit board (PCB), a bread board, an insulated metal substrate (IMS) board, etc. The base members 208, 209 may be, and not limited to, a multi-layered PCB, a rigid PCB, flexible PCB, single layer PCB, aluminum backed PCB, etc. The electronic components 202 are mounted in a predetermined sequence on the base members 208, 209 and accompanied by heat transfer bridges, such as, 204. The heat transfer bridges 204 are in thermal contact with the electronic components 202 to extract and dissipate the heat generated by the components 202. The longitudinal direction of the base members 208, 209 is indicated by the arrow Y-Y’ and the lateral direction of the base member 208, 209 is indicated by the arrow X-X’. The electronic components 202 are positioned along the lateral direction and the longitudinal direction of the base members 208, 209 in the predetermined sequence. The electronic components 202 are, for example, transistors, such as, BJTs, MOSFETs, capacitors, resistors, ICs, voltage converter board, etc. The heat transfer bridges 204 are spread in the lateral direction and the longitudinal direction of the base members 208, 209 to remain in thermal contact with the electronic components 202.
[00035] The heat transfer bridges 204 and two cooling rails 210, 211 are positioned along the longitudinal direction YY’ of the base members 208, 209 The cooling rails 210, 211 are positioned proximal to the longitudinal sides of the base member 208, 209 and extend in the longitudinal direction YY’. The cooling rails 210, 211 carry coolant along the longitudinal direction YY’ of the base members 208, 209. The coolant in the cooling rails 210, 211 flows through the heat transfer bridges 204 to extract heat from the transistors, the capacitors, and the voltage converter respectively and cool the components 202. The heat transfer bridges 204 extend between the cooling rails 210, 211 in the lateral direction XX’ of the base members 208, 209.
[00036] The cooling rail 210 comprises an inlet nozzle 210a removably engaging with an end of the cooling rail 210 and an end cap removably engaging with the other end. Similarly, the cooling rail 211 comprises an outlet nozzle 211a removably engaging with an end and an end cap with the other end. The inlet nozzle 210a and the outlet nozzle 211a are in longitudinally opposite directions. In an embodiment, the inlet nozzle 210a and the outlet nozzle 211a are in the same direction. The coolant flows into the cooling rail 210 through the inlet nozzle 210a and flows out of the cooling rail 211 through the outlet nozzle 211a. The temperature of the coolant exiting from the outlet nozzle 211a is substantially higher than the temperature of the coolant entering through the inlet nozzle 210a, due to the amount of heat carried away by the coolant while exiting through the outlet nozzle 211a. In an embodiment, the coolant exiting from the outlet nozzle 211a may be cooled and re-circulated into the inlet nozzle 210a through an external recirculation line. The coolant may be water, ethylene glycol, etc.
[00037] In an embodiment, the longitudinal sides of the base member 208, 209 are slid into side mounting provisions of the cooling rails 210, 211 for positioning the cooling rails 210, 211 proximal to the longitudinal sides of the base members 208, 209 In an embodiment, the cooling rails 210, 211 have mounting provisions on a bottom surface or a top surface to removably attach the cooling rails 210, 211 to the base members 208, 209 using attachment means, such as, fasteners.
[00038] The electronic assembly 201 of the electronic product 100 comprises at least one terminal block 206 mounted on one of the base members 208. The electrical terminals 203a-203f of the electronic product 100 extend from the terminal block 206. The electrical terminals 203a-203f may be fastened to the terminal block 206 by means of fasteners or any known attachment means or the terminals 203a-203f or may be en-moulded into the terminal block 206. It is through these terminals 203a-203f that the electronic product 100, may be, a controller is connected between a battery and a motor in the electric or hybrid electric vehicle. The base member 208 may be a power board that regulates the power supply from the battery to the motor. The base member 208 may be handling very high voltages to drive the motor. The electrical terminals 203a- 203f are connected to the battery and the motor by means of high voltage cables 205 that are thick and heavy. The connection between the cables 205 and the terminals 203a-203f is established using cable lugs, such as, eyelets 213 shown in Fig. 2A or high-power connectors 213 shown in Fig. 2C. The electrical terminals 203a-203f protrude outwards from the end cover 104. Few of the electrical terminals 203b, 203f are connected to the battery and the other few are connected to the motor. The terminal block 206 is positioned proximal to a lateral edge 208a (shown in Fig. 2C) of the base member 208 and is mounted to a top surface 208b of the base member 208 via multiple fasteners 214 fastened on the bottom surface 208c as shown in Fig. 2D. The electrical terminals 203a-203f are connected to the electronic components 202 on the base member 208 by bus bars 212 that run in the bottom surface 208c of the base member 208. The terminals 203a-203f are of same length and diameter or varying dimensions.
[00039] The electronic assembly 201 further comprises a support assembly 207 that is positioned on a top surface of the terminal block 206 and is configured to distribute the load experienced by the electrical terminals 203a-203f to a packaging member 210, 211 in the electronic product 100. In an embodiment, the packaging member is the pair of cooling rails 210, 211 alongside the base member 208. The support assembly 207 avoids transfer of whole of the load from the electrical terminals 203a-203f to the base member 208.
[00040] The support assembly 207 comprises a support member 215 with primary apertures 301 (shown in Fig. 2D ) and a sleeve 216 with secondary apertures 302 encapsulating the support member 215 at least partially. The support assembly 207 is mounted by means of multiple fasteners 217 inserted into the primary apertures 301 (shown in Fig 3) and the secondary apertures 302. In an embodiment, the support assembly 207 comprises multiple bush members 303 (shown in Fig. 3). A bush member 303 is inserted in each of the secondary apertures 302 and the primary apertures 301. In such an embodiment, the fasteners 217 are inserted into the bush members 303. The primary apertures 301 and the secondary apertures 302 are in-line with each other. The apertures on the terminal block 206 to mount the support assembly 207 are in-line with the primary apertures 301 and the secondary apertures 302. The locations for fastening the base member 208 to the terminal block 206 in the bottom surface 208c of the base member 208 is also in-line with the primary apertures 301 and the secondary apertures 302 as indicated in region R in Fig. 2D. The locations in the bottom surface 208c of the base member 208 is provided very proximal to the lateral edge 208a of the base member 208.
[00041] As can be seen in Fig. 2D, a pair of the fasteners 217 are fastened to the terminal block 206 above the location of each of the electrical terminals 203a- 203f to mount the support assembly 207. Also, a wing portion 215a of the support member 215 is not enclosed within the sleeve 216. This wing portion 215a of the support member is connected to raised openings in the cooling rails 209, 210. The wing portion 215a extends from the side of the planar surface 215b of the support member 215.
[00042] Fig. 3 exemplarily illustrates an exploded view of the support assembly 207. As seen, the shape of the support member 215 is similar as the sleeve 216. However, the sleeve 216 has cutouts for the wing portion 215a of the support member 215 to be exposed. The sleeve 216 is an external insulating cover to the metallic support member 215. Both the sleeve 216 and the support member 215 have arcuate edges 304 and 305 respectively. The planar surface 215b of the planar support member 215 is covered by the planar surface 216a of the sleeve 216. The wing portion 215a extends from the arcuate edge 304 of the support member 215 and extends beyond the sleeve 216. The primary apertures 301 and the secondary apertures 302 are visible on the planar surface 215b, 216a of the support member 215 and the sleeve 216 respectively. A pair of apertures 217 are formed in the location of the support member 215 and the sleeve 216 that is mounted above each electrical terminal 203a-203f. The wing portion 215a also has apertures 306 to mount the support member 215 to the cooling rails 210, 211. The bush members 303 are inserted into the apertures 302, 301 on the planar surfaces 216a, 215b, and then the fasteners 217 are inserted into them.
[00043] To assemble the electronic assembly 201, the apertures on the top surface 208b and the bottom surface 208c of the base member 208 are made proximal to the lateral edge 208a and the terminal block 206 is fastened to the base member 208 from the bottom surface 208c. On the top surface of the terminal block 206, the support assembly 207 is positioned such that the secondary apertures 302 are in-line with the mounting locations on the top surface of the terminal block 206 and then the fasteners 217 are positioned. In addition, the wing portion 215a of the support member 215 is fastened to the cooling rails 210, 211 that are positioned proximal to the longitudinal sides of the base member 208. The support assembly 207 is assembled by enclosing the support member 215 into the sleeve 216 and inserting the bush members 303 in the primary apertures 301 and the secondary apertures 302. A similar configuration of the support assembly is possible to be implemented in the other base members, such as, 209.
[00044] The electronic product with the electronic product with the support assembly as disclosed in the present invention provides the following technical advancement in the field of design of electronic products: During normal operation of the electronic products, the temperature of electronic components within rises. During charging, overcharging, and extended operation, the temperatures may drastically rise. In both these conditions, the heat dissipation assembly and its associated components, such as the coolant, the cooling rails, the bridges, extract and dissipate the heat away from the electronic components. The bridges reduce the temperature of the individual electronic components, such as, transistors, capacitors, etc., and subsequently cool the electronic assembly and the electronic product actively and efficiently. The assembly of the bridges along with the electronic components ensures a compact packaging of the electronic assembly and the electronic product.
[00045] The torsional load that is experienced by mounting the electrical terminals tightly over the base member are not transferred to the base member due to the presence of the support assembly. Also, the pull and push motion that the electrical terminals experience due to the connection of the heavy thick cables on the electrical terminals is also not transferred to the base member. The support member of the support assembly is encapsulated in the sleeve. The sleeve is made of plastic or resin and insulates the connection of the metallic part with the electrical terminals. The terminal block ensures the electrical terminals are distinctly positioned and do not come in contact with one another. The torsional load is transmitted from the electrical terminals to the packaging member, which in this case is a pair of cooling rails. The cooling rails are already existing in the electronic product and the load is transmitted to them. There is no need for additional packaging members to be mounted to eliminate transfer of load from the electrical terminals to the base member.
[00046] The arcuate edges of the support member and the sleeve ensure the packaging of the support assembly within the electronic product is compact. The sleeve also provides electrical isolation of the metal support member and the electrical terminals from the base member also and thus prevents short circuit. The bush member within the apertures of the support member and the sleeve also provides electrical isolation between the electrical terminals and the support member.
[00047] The design of the electronic assembly with the heat dissipation assembly ensures cooling of all the major thermal contributors in the electronic assembly. The assembly of the electronic components on the base members and the assembly of the components of the heat dissipation assembly are not cumbersome and are guided by the features of the components, such as, the inlet port, the outlet port, the end caps, the nozzles, etc.
[00048] Due to the compact packaging of the electronic assembly and support assembly within the casing, the dimensions of the electronic product are also reduced, making space for other additional features in a space crunched vehicle. The components of the electronic product are all modular and can be added to the existing circuit design of the existing electronic product with ease, to achieve prolonged operation of the electronic product, higher efficiency throughout its operation, and avoiding occurrences of any kind of catastrophes in the space crunched applications. The heat dissipation assembly can also function along with existing cooling mechanism of the electronic product.
[00049] The components of the heat dissipation assembly and the support assembly are light weight, have features that guide in mounting while assembly, maintenance, and servicing, and are thin so as not to occupy more space, it makes the electronic product compact, as well as safe to use, preventing thermal runaway and elevated operating temperatures. The electronic product with such an electronic assembly has wattage in the range of about 0-50 kW and finds application in space constrained mobile devices, products, vehicle, such, two-wheelers, three-wheelers, or any multi-wheeled vehicle, such passenger trucks that experience lot of shock and vibrations. The components of the electronic assembly are tightly lodged into the base members with electrical insulation between the electrical terminals. The support assembly also provides mechanical support to the electrical terminals.
[00050] Thus, the support assembly as per present invention provides mechanical stability, thermal stability, durability, vibration isolation, and impact resistance to the base member of the electronic assembly while enabling breaking of trade-off on variety creation versus ease of manufacturing and assembly leading to a reliable electronic product for a powered device along with a robust casing capable of withstanding various loads arising out of its usage as well as its process of assembly cum manufacturing.
[00051] Improvements and modifications may be incorporated herein without deviating from the scope of the invention.


LIST OF REFERENCE NUMERALS
100- Electronic product
101- Casing
102- fins
103- First end cover
104- Second end cover
104a- provision for electrical terminal
201- electronic assembly
202-electronic components
203a-203f- electrical terminals
204- heat transfer bridges
205-cables
206- terminal block
207-support assembly
208, 209- base member
208a- lateral edge of base member 208
208b- top surface
208c-bottom surface
210, 211- cooling rails/packaging member
210a- inlet nozzle
211a-outlet nozzle
212- bus bars
213- connecting lugs (eyelets)
214- fasteners on bottom surface 208c
215- support member
215a-wing portion
215b- planar surface of support member
216-sleeve
216a-planar surface of sleeve
217- fasteners
301- primary apertures
302-secondary apertures
303-bush members
304-arcuate edges of support member
305- arcuate edges of sleeve
306- apertures in wing portion