Double Busbar Shielding Structure for Compact EV Heat Dissipation
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Solution Overview
Problem
Existing current routing systems in vehicles, particularly electric vehicles, face challenges in achieving simplified, highly resilient, and compact designs due to the increasing voltages and currents, which often result in overheating and electrical malfunctions.
Innovation Solution
A double busbar device with insulated first and second busbar units and a tubular shielding unit made of solid metal, where the busbar units are in mechanical contact with the shielding unit over a large area, enhancing heat dissipation and preventing wrinkling or damage, allowing for a compact and resilient current routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If busbar units are arranged close together to achieve compact current routing, then space utilization is improved, but heat dissipation becomes insufficient leading to overheating
Solution Approach 1:
A shielding unit made of thermally conductive material is introduced as an intermediary between the busbar units and the environment. This shielding unit serves dual purposes: providing electromagnetic shielding while acting as a heat dissipation pathway. The shielding unit includes thermal management features such as heat sinks or cooling channels that facilitate efficient heat transfer from the busbar units to the surrounding environment, resolving the contradiction between compact arrangement and adequate heat dissipation.
2Reliability
If insulating sheathing layers are protected to prevent damage, then reliability is improved, but the structure becomes more complex and vulnerable to wrinkling
Solution Approach 1:
The shielding unit is positioned and configured in advance to provide mechanical protection and support to the insulating sheathing layers of the busbar units. By establishing this protective structure beforehand, the sheathing layers are cushioned against external forces that could cause wrinkling or damage during installation and operation, thereby improving reliability without requiring additional complex protective structures.
3Object-affected harmful factors
If shielding unit is added to protect electronic components, then electromagnetic shielding is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The shielding unit is designed with specific material parameters and structural parameters that enable it to perform both electromagnetic shielding and heat dissipation functions. The material composition, thickness, and geometric configuration of the shielding unit are optimized to maintain electromagnetic屏蔽 performance while providing adequate thermal conductivity and surface area for heat dissipation, thus resolving the contradiction between shielding effectiveness and thermal management.
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
The solution provides a compact, safe, and resilient current routing system that prevents overheating and electrical malfunctions by improving heat dissipation and reducing the risk of damage to insulating sheathing layers, while allowing for flexible installation in vehicles.
Implementation Method 1
a summation shielding unit (4) with a tubular shielding element (4a) made of solid metal, in particular aluminum
Implementation Method 2
The busbar units (2, 3) are in mechanical contact with an inner surface (4b) of the summation shielding unit (4) over a large area of their respective outer surface (2c, 3c)
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3~4
AI summary
The disclosure relates to a double busbar device (1) for a vehicle, in particular for an electric vehicle, having a first busbar unit (2) which has an insulating first sheath layer element (2b); and having a second busbar unit (3) which has an insulating second sheath layer element (3b), the first and second busbar units (2, 3) being arranged insulated from one another by means of the sheath layer elements (2b, 3b) and following a course of the double busbar device (1); and with a summation shielding unit (4) with a tubular shielding element (4a) made of solid metal, wherein in a cross-section transverse to the course the first and second busbar units (2, 3) are in mechanical contact with an inner surface (4b) of the summation shielding unit (4) over a large area with their outer surface (2c, 3c) in order to realize an improved, in particular a simplified, heavy-duty current routing in a vehicle.