Heat Dissipation Bolt for Isolated Busbar Cooling
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Solution Overview
Problem
Power distribution units (PDUs) experience uneven heat distribution, particularly at isolated busbars between heat-generating components like fuses and relays, leading to thermal issues that can affect component performance and increase the risk of failure.
Innovation Solution
Incorporation of a heat dissipation bolt made of steel and ceramic, which is bolted through the busbar and housing, providing a direct path for heat transfer while maintaining electrical isolation and supporting the busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If busbars are disposed between two heat-generating devices (fuse and relay), then the PDU can achieve compact layout and efficient power distribution, but the busbar cannot dissipate heat quickly enough leading to thermal issues
Solution Approach 1:
A heat dissipation bolt is introduced as an intermediary component between the busbar and the metal housing. This bolt provides a dedicated thermal conduction path that mediates heat transfer from the busbar to the housing, resolving the thermal accumulation problem while preserving the compact layout.
Solution Approach 2:
The heat dissipation function is extracted from the busbar itself and transferred to a separate dedicated component (the heat dissipation bolt). This allows the busbar to focus on its primary electrical conduction function while the bolt handles thermal management, improving overall system thermal performance.
2Temperature
If heat dissipation bolt is added to improve heat dissipation, then thermal issues are resolved, but the device structure becomes more complex
Solution Approach 1:
The heat dissipation bolt is designed to perform multiple functions simultaneously: it provides thermal conduction from the busbar to the housing, maintains electrical isolation through its ceramic body, and offers mechanical support to the busbar. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in structural complexity.
Solution Approach 2:
The heat dissipation function is merged with the existing structural framework by utilizing the metal housing as a heat sink. The heat dissipation bolt integrates thermal management into the existing housing structure rather than requiring a separate cooling system, minimizing additional complexity.
3Reliability
If heat dissipation bolt with ceramic body is used, then electrical isolation is maintained while heat transfer occurs, but manufacturing complexity increases
Solution Approach 1:
The heat dissipation bolt employs a composite structure with a ceramic body and metal threaded portions. The ceramic material provides electrical insulation and thermal conduction properties, while the metal threads enable mechanical fastening. This composite approach achieves both electrical isolation and heat transfer functionality in a single integrated component.
Solution Approach 2:
The heat dissipation bolt is segmented into distinct functional zones: ceramic portions for electrical isolation and thermal conduction, and metal threaded portions for mechanical fastening. This segmentation allows each material to be optimized for its specific function while simplifying the manufacturing process by enabling modular production and assembly.
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 heat dissipation bolt efficiently transfers heat away from the busbar to the housing, maintaining uniform temperature and reducing the risk of component failure by enhancing heat dissipation and providing structural support.
Implementation Method 1
The heat dissipation bolt efficiently transfers heat away from the busbar to the housing
Implementation Method 2
A ceramic body in the middle of the heat dissipation bolt ensures that current does not pass through the heat dissipation bolt
Data Source
AI summary
A power distribution unit includes a fuse, a relay, a busbar, and a heat dissipation bolt. The fuse and the relay each have one terminal. The busbar is located between the fuse and the relay and connects to the two terminals. The heat dissipation bolt connects the busbar to a housing of the power distribution unit and includes two threaded bolts, one going through the busbar and the other going through the housing.