Stacked DC-DC Converter Assembly With Isolated Busbars
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Solution Overview
Problem
Existing voltage conversion systems in electric and hybrid vehicles face challenges in efficiently managing high voltage outputs from rechargeable energy storage systems (RESS) to power vehicle accessories, necessitating improved efficiency and reliability in DC-to-DC voltage conversion.
Innovation Solution
A redundant power converter system with a stacked configuration using isolated busbars and a casing that includes printed circuit boards and conductive members for electrical isolation and heat management, along with electromagnetic shielding, to convert and distribute electrical current efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple power converters are used to convert voltage from RESS to 12-volt level, then reliability and redundancy are improved, but device complexity and space requirements increase
Solution Approach 1:
Multiple power converters are merged into a single integrated assembly with shared housing, cooling system, and electrical connections. The converters are mounted side-by-side within a common enclosure, sharing structural support and thermal management infrastructure, which reduces overall system complexity while maintaining redundancy
Solution Approach 2:
The common housing serves multiple functions: structural enclosure, thermal management housing, electrical isolation barrier, and mounting structure. The cooling system serves all converters simultaneously, and the housing provides both mechanical protection and electrical isolation, reducing the need for separate components for each converter
2Reliability
If multiple power converters are used for voltage conversion, then redundancy and reliability are improved, but the space required for the system increases
Solution Approach 1:
Multiple power converters are nested within a single common housing enclosure. The converters are arranged in a compact configuration inside the shared housing, with electrical connections and cooling channels integrated into the same space, significantly reducing the total volume required compared to separate converter assemblies
Solution Approach 2:
Multiple converters share common infrastructure including housing, cooling system, and mounting structures. This consolidation eliminates redundant structural elements and allows efficient packing of converters within the available space, reducing overall system volume
3Volume of moving object
If power converters are closely integrated in a stacked configuration, then space is reduced, but thermal management becomes more challenging
Solution Approach 1:
A common cooling system acts as an intermediary between the closely packed converters and the external environment. The cooling channels and fluid distribution system are integrated into the housing structure, efficiently extracting heat from multiple converters simultaneously and distributing it throughout the cooling infrastructure
Solution Approach 2:
The housing structure serves dual functions as both mechanical enclosure and thermal management system. The housing incorporates integrated cooling channels that directly contact the converters, allowing the same structural element to provide both protection and active cooling
4Reliability
If electrical isolation is implemented between busbars and casing, then safety and reliability are improved, but manufacturing complexity increases
Solution Approach 1:
Electrical isolation features are merged into the housing design itself rather than being separate components. The housing incorporates non-conductive materials or integrated insulation layers as part of the manufacturing process, eliminating the need for separate isolation components and simplifying assembly
Solution Approach 2:
The housing structure provides its own electrical isolation function through material selection or design features built into the manufacturing process. The isolation capability is inherent to the housing rather than requiring additional components, making the system self-sufficient and easier to manufacture
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 system enhances the efficiency and reliability of voltage conversion by providing redundant power pathways, reducing space requirements, and improving thermal management while maintaining electrical isolation and electromagnetic protection.
Implementation Method 1
at least two power converters configured to convert an electrical current from a primary voltage to a secondary voltage
Implementation Method 2
the casing may be configured to conduct heat from the power converters
Implementation Method 3
isolation layers enclosed within the casing and disposed between each of the at least two busbars and between the at least two busbars and the casing
Data Source
AI summary
Systems and methods are provided for voltage conversion. The systems include power converters configured to convert an electrical current from a primary voltage to a secondary voltage, a casing, wherein the power converters are secured to exterior surfaces of the casing, a stack that includes busbars enclosed within the casing that are each configured to conduct the electrical current at the secondary voltage from the power converters, wherein each of the busbars are electrically isolated from each other and from the casing, wherein a first power converter is electrically coupled to a first busbar and not to a second busbar, and a second power converter is electrically coupled to the second busbar and not to the first busbar, and terminals secured to the casing and configured to conduct the electrical current at the secondary voltage from the busbars to an electrical system.