Mesh Busbar for Flexible Electrical Coupling and Thermal Management
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Solution Overview
Problem
Conventional busbars in electrified vehicles lack flexibility and efficient thermal management, making them less suitable for the complex power distribution and cooling needs of electric vehicles.
Innovation Solution
A mesh busbar design with woven metal strands in an over-and-under pattern, featuring openings for thermal exchange and the ability to be flexed and bent, secured with fasteners through strategically placed openings, and potentially including multiple folded mesh layers for enhanced current carrying capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional solid busbars are used, then electrical connection is achieved, but flexibility and thermal management are poor
Solution Approach 1:
The busbar is transformed from a solid continuous structure into a mesh structure composed of multiple interconnected conductive elements forming openings. This segmentation provides flexibility while maintaining electrical conductivity through the network of conductive paths, and enables thermal management through the openings that facilitate heat dissipation.
Solution Approach 2:
The busbar incorporates a mesh structure with multiple openings throughout its body, creating a porous configuration that allows fluid flow for thermal management. The porous structure maintains electrical conductivity through the conductive material network while enabling cooling functions that solid busbars cannot provide.
2Temperature
If mesh busbar with openings is used, then thermal management is improved, but structural strength may be reduced
Solution Approach 1:
The busbar employs a composite structure combining conductive material with a mesh configuration, creating a material system that simultaneously provides electrical conductivity, mechanical strength, and thermal management capabilities. The composite nature allows optimization of each function without compromising the others.
Solution Approach 2:
The mesh structure incorporates curved and folded elements rather than straight rigid components, allowing the busbar to bend and flex while maintaining structural integrity. The curved geometry distributes stress more effectively than straight edges, preserving strength despite the presence of openings.
3Power
If multiple mesh layers are folded and secured with fasteners, then current carrying capacity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The busbar structure incorporates multiple mesh layers nested within each other, with inner layers positioned inside outer layers. This nesting arrangement increases the effective cross-sectional area for current carrying while maintaining a compact overall form factor. The layers are secured together through fasteners that pass through aligned openings.
Solution Approach 2:
The busbar transitions from a two-dimensional flat mesh to a three-dimensional structure by folding and layering multiple meshes in the vertical dimension. This adds depth and volume to the conductive path network, significantly increasing current carrying capacity while the modular layered approach facilitates systematic manufacturing.
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 mesh busbar provides efficient electrical coupling, enhanced thermal management, and reduced weight compared to solid busbars, accommodating complex powertrain configurations and cooling requirements in electrified vehicles.
Implementation Method 1
a mesh busbar configured to electrically couple a first component to a second component
Implementation Method 2
The mesh busbar provides openings, which can facilitate an exchange of thermal energy between the busbar assembly and the surrounding environment
Implementation Method 3
The mesh busbar provides openings, which can facilitate an exchange of thermal energy between the busbar assembly and the surrounding environment
Data Source
AI summary
A busbar assembly includes a mesh busbar configured to electrically couple a first component to a second component. An electrical coupling method including securing a mesh busbar to a first component and a second component to electrical couple the first component to the second component.