Busbar Thermal Isolation Structure for High-Current Power Distribution

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Solution Overview

Problem

The challenge in electric vehicles is the temperature increase of busbars due to high current flow, limiting voltage and current capacity, which affects charging speed and power distribution efficiency.

Innovation Solution

Incorporating a thermal component, such as a cold plate, over-molded with an electrically isolating material, to dissipate heat from busbars, allowing for higher current and voltage capacity while maintaining electrical isolation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If busbars carry high current to enable fast charging and power distribution, then power delivery capability is improved, but temperature increases due to resistive heating

Engineering Contradiction:

Improvepower delivery capabilityVSAvoidbusbar temperature

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent introduces a thermal component as an intermediary between the busbar and the housing. This thermal component conducts heat away from the busbar through thermal contact, while the electrically isolating material prevents electrical current from flowing through the thermal component. This mediator approach allows heat transfer without electrical conduction, resolving the contradiction between high power delivery and temperature control.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the need for complex active cooling systems with a passive thermal management approach using conductive materials and geometric design. The thermal component and housing structure create natural heat dissipation pathways, substituting mechanical cooling systems with a thermally conductive structural design that manages heat passively while maintaining electrical isolation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If thermal component is placed in direct contact with busbar for heat dissipation, then cooling efficiency is improved, but electrical isolation is compromised

Engineering Contradiction:

Improvebusbar cooling efficiencyVSAvoidelectrical isolation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent employs composite material construction where a thermal component made of thermally conductive material is combined with an electrically isolating material. This composite structure allows the thermal component to maintain high thermal conductivity for efficient heat dissipation while the electrically isolating material layer prevents electrical current flow, simultaneously achieving both cooling efficiency and electrical isolation reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material properties to different regions of the thermal management system. The portion of the thermal component in contact with the busbar has high thermal conductivity for heat transfer, while the outer surface or surrounding areas are covered with electrically isolating material. This local differentiation of material properties enables simultaneous thermal management and electrical isolation without compromising either function.

Inventive Principle:

Principle #3Local quality

3Power

If busbar size is increased to handle higher currents, then power capacity is improved, but device weight and volume increase

Engineering Contradiction:

Improvecurrent carrying capacityVSAvoidbusbar weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The patent introduces a thermal component as an intermediary thermal management system that allows busbars to operate at higher currents by actively managing heat dissipation. This intermediary thermal control system enables the busbar to sustain higher power loads without requiring an increase in busbar cross-sectional area, thereby maintaining lower weight while achieving higher current carrying capacity through improved thermal management.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables efficient power distribution with reduced busbar size and weight, enhancing charging speed and power delivery to vehicle components.

Implementation Method 1

a thermal component to dissipate heat generated at the busbar

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The material can be an electrically isolating material such as a plastic. The electrically isolating material can be molded over a portion, or an entirety, of an outer surface of the thermal component. The material can prevent current from flowing through the thermal component.

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Implementation Method 3

The busbars can increase in temperature due to current carried by the busbar based on a voltage applied to the busbars

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS12555992B2Power distribution device with a thermal component

Publication Date: 2026.02.17 RIVIAN HOLDINGS LLC

AI summary

A power distribution device with an electric component is provided. The device can include a busbar. The device can include a thermal component coupled to the busbar to dissipate heat generated at the busbar. The device can include a material molded over at least a portion of the thermal component to electrically isolate at least the portion of the thermal component from the busbar.