BEV Power Distribution Module With Isolated Busbar Layout
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Solution Overview
Problem
Battery electric vehicles face congestion and complexity in connecting power, ground, and signal cables, as well as coolant pipes, making maintenance and service difficult due to the large number of components.
Innovation Solution
An electrical power distribution module with an upper module containing a circuit board and temperature control system, and a lower module with isolated busbars arranged in alternating polarity to provide organized power and ground connections for vehicle components, reducing the need for individual cable routing and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual cable routing is used for power, ground, and signal connections, then electrical connections can be established, but cable congestion and complexity increase making service difficult
Solution Approach 1:
The patent combines multiple individual cable connections (power, ground, signal) into a single integrated connector assembly. The connector includes multiple contact elements arranged in a structured pattern that simultaneously establishes all necessary electrical connections, eliminating the need for separate cable routing for each connection type.
Solution Approach 2:
The connector is designed as a universal interface that handles multiple functions simultaneously - power transmission, ground connection, and signal communication - all through a single connection point. This multi-functional connector reduces the overall number of components and simplifies the electrical architecture.
2Adaptability or versatility
If multiple components are mounted in the vehicle, then vehicle functionality is enhanced, but mounting space requirements increase
Solution Approach 1:
The patent integrates multiple electrical connection functions into a single compact connector assembly that occupies minimal mounting space. By combining power, ground, and signal connections in one unit, the space required for electrical component mounting is significantly reduced compared to separate connectors for each function.
Solution Approach 2:
The connector design nests multiple contact elements and electrical pathways within a compact structure. The contact elements are arranged in a nested or layered configuration that maximizes functional density while minimizing the overall footprint required for mounting.
3Ease of repair
If service access is provided for individual cables, then maintenance can be performed, but cable congestion makes work difficult
Solution Approach 1:
The integrated connector provides a single access point for all electrical connections, allowing service personnel to maintain or replace the entire electrical interface by working with one component rather than navigating through congested individual cables. This significantly improves ease of operation during service.
Solution Approach 2:
The connector is designed as a removable module that can be easily extracted from the vehicle system for maintenance or replacement. This extraction capability allows service personnel to remove the entire electrical connection assembly without having to work with individual cables, making maintenance straightforward despite the complexity of the electrical connections within.
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 solution reduces the required space for mounting components, enhances safety during assembly, and provides secure electrical connections while protecting against the road environment, resulting in a lighter and more efficient vehicle design.
Implementation Method 1
a temperature control system, the temperature control system configured to control a temperature of the at least one circuit board
Implementation Method 2
each isolated busbar is electrically connected to the plurality of electrical connectors having corresponding voltages and polarity, wherein the plurality of isolated busbars are electrically connected to the at least one circuit board
Data Source
AI summary
An electrical power distribution module for a vehicle. The electrical power distribution module provided with an upper module and a lower module. The upper module provided with circuit boards for various vehicle components and a temperature control system. The lower module provided with a plurality of isolated busbars, isolated from the surrounding structure. Each isolated busbar is one of a positive busbar, a negative busbar, and a ground busbar. The plurality of isolated busbars are arranged on opposite sides of the lower module and are arranged in an alternating fashion based on polarity. The plurality of isolated busbars are electrically connected to the circuit boards. The plurality of electrical connectors are spaced apart from each other and are configured to provide power and ground connections for the vehicle components. The plurality of isolated busbars are configured to carry different voltages.