Alternating Busbars for Power Module Thermal Management
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Solution Overview
Problem
Current power module assemblies for electrified vehicles face challenges in efficiently connecting and supporting power stages with opposite polarity terminals, leading to potential electrical inefficiencies and thermal management issues due to the lack of a structured and efficient busbar arrangement.
Innovation Solution
The proposed solution involves an array of stacked power stages with U-shaped busbars that alternately connect like-polarity terminals, supported by external frames with passthroughs, and a protective housing to secure and thermally manage the assembly, ensuring efficient electrical connectivity and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If busbars are arranged to connect like-polarity terminals in an alternating sequence, then electrical efficiency is improved, but device complexity increases due to the structured arrangement requirements
Solution Approach 1:
The busbar arrangement is segmented into alternating positive and negative busbars, each connecting like-polarity terminals from adjacent power stages. This segmentation creates a modular alternating sequence that improves electrical efficiency while maintaining manageable complexity through repetitive patterns.
Solution Approach 2:
The busbars are arranged asymmetrically with respect to polarity alternation, where positive busbars connect positive terminals and negative busbars connect negative terminals in an alternating sequence along the array of power stages. This asymmetric polarity arrangement optimizes electrical connectivity.
2Reliability
If power stages are stacked in an array with adjacent terminals of same polarity, then electrical connectivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The array of power stages is segmented into repeating units where each stage has terminals of the same polarity positioned adjacently. This segmentation creates a predictable pattern that improves electrical connectivity while allowing standardization that can offset manufacturing precision challenges.
Solution Approach 2:
Each power stage is designed with local terminal positioning optimized for same-polarity adjacency, while the overall array maintains a standardized stacking pattern. This local optimization of terminal arrangement improves connectivity without requiring excessive global manufacturing precision.
3Temperature
If busbars are dispersed alternately along the side face of frames, then thermal management is improved, but device complexity increases
Solution Approach 1:
The busbars are segmented and dispersed alternately along the side face of the frames, creating distinct thermal zones for positive and negative busbars. This segmentation improves thermal management by distributing heat sources while maintaining a repetitive pattern that controls complexity.
Solution Approach 2:
The busbar arrangement extends into the spatial dimension along the side face of the frames, dispersing busbars in a linear sequence rather than concentrating them. This dimensional distribution improves thermal management by spreading heat generation across a larger surface area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances electrical efficiency by ensuring precise and alternating busbar placement, supports efficient thermal management through coolant delivery, and maintains structural integrity, addressing the inefficiencies and thermal challenges in existing power module assemblies.
Implementation Method 1
The busbars are dispersed along the array to electrically connect like polarity terminals
Implementation Method 2
A protective layer may be molded over and covering the array of stacked frames such that the terminals extend through the layer
Data Source
AI summary
A vehicle power module assembly is provided. The assembly many include an array of stacked frames, a power stage housed within each of the frames, and busbars. Each of the power stages may include a pair of opposite polarity terminals extending therefrom. The busbars may be dispersed along the array to electrically connect like polarity terminals. The power stages may be arranged with one another such that like polarity terminals are adjacent one another and the busbars define an alternating sequence corresponding to the polarity of the terminals. The terminals may be located on the respective power stages such that the busbars are alternately dispersed in a linear sequence along a side face defined by portions of the frames.