Segmented Busbar Thermal Management via Layer Spacing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional busbars in electrified vehicles lack efficient thermal management, as they do not effectively facilitate heat exchange between the busbar and the surrounding environment, leading to slower cooling of components.
Innovation Solution
A flexible busbar assembly with multiple layers, where some layers are spaced to create openings, allowing for enhanced thermal energy exchange by exposing more surface area and facilitating airflow or fluid movement through these openings, thereby improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple layers are stacked closely together in a busbar, then structural integrity and electrical connectivity are maintained, but thermal exchange with the environment is limited
Solution Approach 1:
The busbar is divided into multiple discrete layers (first layer, second layer, third layer) that can be independently positioned. By segmenting the structure, openings are created between layers to enhance thermal exchange, while maintaining overall structural integrity through selective contact points and support features.
Solution Approach 2:
The patent introduces vertical spacing between horizontal layers, adding a dimensional aspect to thermal management. The openings between layers create vertical pathways for airflow and thermal exchange, transforming a traditionally two-dimensional heat dissipation problem into a three-dimensional thermal management solution.
2Temperature
If layers are spaced apart to create openings, then thermal energy exchange is enhanced, but structural stability may be compromised
Solution Approach 1:
Different regions of the busbar structure have different properties: some areas have spaced layers for thermal exchange, while other areas have contact points and support features for structural stability. The insulating coating is applied selectively at contact points, and the opening configurations vary between different sections to balance thermal and structural requirements locally.
Solution Approach 2:
Insulating coatings and support features act as intermediaries between the spaced layers. These elements maintain the intended spacing to enable thermal exchange while preventing direct contact that would compromise the opening's effectiveness, thus mediating between the competing requirements of thermal performance and structural stability.
3Ease of manufacture
If conventional single-layer busbar design is used, then manufacturing is simpler, but cooling performance is insufficient
Solution Approach 1:
The busbar is segmented into multiple manufacturable layers that can be produced and then assembled. This segmentation allows each layer to be manufactured using conventional processes, while the assembled multi-layer structure achieves superior cooling performance through the created openings and increased surface area exposure.
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 busbar assembly achieves faster cooling of both the busbar and connected components by increasing thermal energy exchange with the environment, which can be further enhanced by using airflow or a thermal exchange plate, maintaining components within a desired temperature range.
Implementation Method 1
enhanced thermal energy exchange by exposing more surface area
Implementation Method 2
facilitating airflow or fluid movement through these openings, thereby improving cooling efficiency
Implementation Method 3
moving a flow of air through the opening to cool the busbar
Data Source
AI summary
An exemplary busbar assembly includes a first layer, and a second layer having a portion that contacts the first layer and a portion that is spaced from the first layer to provide an opening between the first layer and the second layer. An exemplary method of managing thermal energy includes contacting a first layer and a second layer in a first area of a busbar, and separating, in a second area of the busbar, the first layer from the second layer to provide an opening between the first layer and the second layer.