Bus Bar Thermal Management via Projected Housing Element
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Solution Overview
Problem
In high-voltage electrical systems, bus bars experience resistance-related heating, which is challenging to dissipate efficiently due to the limited thermal conductivity of plastic housings, leading to potential damage and reduced system performance.
Innovation Solution
An electrical system with optimized heat dissipation is achieved by incorporating a bus bar, a housing element with a projecting shaped element, and a heat-conducting element that contacts the bus bar thermally. The heat-conducting element, often a gap pad or TIM, is designed to transfer heat efficiently to the housing element, which has high thermal conductivity, thereby dissipating heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is dissipated via a plastic housing, then the housing provides structural protection, but the plastic material has low thermal conductivity which limits heat dissipation efficiency
Solution Approach 1:
A heat-conducting element is introduced as an intermediary component between the bus bar and the plastic housing. This element has high thermal conductivity to efficiently transfer heat from the bus bar, while its geometric design (projecting shaped element) ensures effective thermal coupling with the housing without requiring direct contact between the bus bar and plastic material.
Solution Approach 2:
The housing element is segmented into a main body and a projecting shaped element that extends toward the bus bar. This segmentation creates a dedicated heat transfer interface (contact surface) that is thermally coupled to the bus bar, separating the heat conduction function from the structural housing function.
2Strength
If a plastic housing is used for protection, then structural integrity is maintained, but heat transfer to the housing is limited due to low thermal conductivity of plastic
Solution Approach 1:
The heat-conducting element serves as a thermal bridge between the bus bar and the plastic housing, enabling efficient heat transfer without compromising the protective function of the plastic housing. The intermediary material has superior thermal conductivity compared to plastic, overcoming the thermal insulation property of the housing material.
3Power
If heat is concentrated in the bus bar, then current conduction is maintained, but resistance-related heating causes overheating and potential damage
Solution Approach 1:
The heat generated by resistance in the bus bar is extracted and transferred to the heat-conducting element, which then conducts it to the housing element. This extraction process removes thermal energy from the bus bar region, preventing overheating while maintaining the bus bar's electrical function.
Solution Approach 2:
The harmful heat generated by electrical resistance is converted into a beneficial thermal management problem that can be systematically solved through the heat-conducting element and housing geometry, transforming the overheating issue into an optimized heat dissipation system.
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 ensures effective heat dissipation from the bus bar, reducing the risk of overheating and damage, while maintaining structural integrity and enhancing the overall performance of the electrical system.
Implementation Method 1
heat from the bus bar is transferred accordingly from the bus bar via the heat-conducting element into the housing element
Implementation Method 2
its surfaces in relation to the surrounding air are large, so the housing element can absorb a lot of heat and/or release it to the surroundings via the surfaces by convection
Data Source
AI summary
An electrical system with optimised heat dissipation and an electrical drive unit having the electrical system is disclosed. The electrical system has a bus bar, a housing element, and a heat-conducting element which contacts the bus bar in a thermally conductive manner. At least part of the housing element includes, on a side facing the bus bar, a shaped element which projects from an outer extension plane and forms a contact surface against which the heat-conducting element (40) bears in a thermally conductive manner.