Bus Bar Cooling Assembly With Insulating Cover for Heat Dissipation
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Solution Overview
Problem
Existing electrical assemblies face challenges in efficiently dissipating heat generated by high-current components, particularly when using active cooling systems, due to inefficiencies in heat transfer and insulation methods.
Innovation Solution
The implementation of a cooling member comprising a tubular member with non-circular cross-sections and a thermally conductive, electrically insulating cover, which is overmolded directly onto the tubular member to enhance thermal coupling and reduce the use of potting material, thereby improving heat dissipation and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling methods with potting material are used, then electrical insulation is provided, but heat dissipation efficiency deteriorates due to poor thermal conductivity
Solution Approach 1:
The patent employs a composite material system consisting of a thermally conductive electrically insulating cover (made from materials like PEEK, PI, or PPS with thermal conductivity of 0.5-2.0 W/m·K) combined with phase change material (PCM) having high latent heat of fusion (150-300 J/g). This composite structure simultaneously achieves effective heat dissipation through the thermally conductive cover and electrical insulation through the insulating properties of both the cover and PCM, resolving the contradiction between heat dissipation efficiency and electrical insulation reliability.
2Reliability
If thicker insulation material is used, then electrical insulation is improved, but thermal coupling efficiency deteriorates
Solution Approach 1:
The patent applies local quality by creating distinct thermal zones: the first portion of the cover directly contacts the tubular member with thin spacing (0.02-0.08 inches) for high thermal coupling, while the second portion extends outward with increased thickness (0.12-0.20 inches) for enhanced electrical insulation. The PCM is localized in the first portion where thermal coupling is critical, while the overall cover structure provides insulation in the second portion, optimizing both thermal and electrical performance in different locations.
3Temperature
If active cooling systems are implemented, then heat dissipation is enhanced, but system complexity increases
Solution Approach 1:
The patent implements self-service through the phase change material that automatically absorbs heat when temperature rises above its melting point and releases heat when temperature drops below its freezing point, without requiring external control systems. The thermally conductive electrically insulating cover passively conducts heat from the tubular member to the PCM and surrounding environment. This passive thermal management system eliminates the need for active cooling components like pumps, valves, or control electronics, reducing system complexity while maintaining effective heat dissipation.
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 heat dissipation and insulation, allowing for effective cooling of high-current electrical components, even at currents exceeding 200 Amps, by increasing thermal conductivity and reducing material thickness, thus optimizing the assembly's performance.
Implementation Method 1
the cover comprising thermally conductive and electrically insulating material
Implementation Method 2
As the cooling fluid 52 flows through the tubular member 40, the cooling fluid 52 absorbs heat generated by the bus bar assembly 32 and/or the electrical component(s) 34, such as via thermal conduction and/or convection
Implementation Method 3
As the cooling fluid 52 flows through the tubular member 40, the cooling fluid 52 absorbs heat generated by the bus bar assembly 32 and/or the electrical component(s) 34, such as via thermal conduction and/or convection
Data Source
AI summary
An assembly includes an electrical component; a bus bar assembly connected with the electrical component; and a cooling member connected with the bus bar assembly, the cooling member including: a tubular member; and a cover enclosing portions of the tubular member, the cover comprising thermally conductive and electrically insulating material. The enclosed portions of the tubular member may include a non-circular cross-section.