Two-Face Heatsink Busbar Layout for High-Voltage Cooling
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Solution Overview
Problem
Existing cooling solutions for electrical busbars in high-voltage electrical equipment, such as those in electric or hybrid vehicles, are insufficient for effective heat dissipation, particularly at voltages above 60V, leading to potential damage from heat generated by the Joule effect.
Innovation Solution
The integration of a busbar with a heatsink that utilizes both opposite faces for cooling, where the busbar comes into direct contact or via intermediate layers with the heatsink, increasing the cooling surface area and efficiency while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling box with circulating cooling liquid is used to cool busbars, then some cooling effect is achieved, but the cooling is insufficient for high-voltage operations above 60V
Solution Approach 1:
The patent transitions from single-face cooling to two-face cooling by utilizing both opposite faces of the heatsink. This dimensional expansion of the cooling interface dramatically increases the heat dissipation surface area, enabling effective cooling for high-voltage operations where conventional single-face cooling becomes insufficient.
Solution Approach 2:
The busbar is integrated directly with the heatsink structure, merging the electrical conductor with the thermal management system. This integration ensures optimal thermal contact between the heat-generating busbar and the cooling surfaces, maximizing heat transfer efficiency while maintaining structural compactness.
2Temperature
If only one face of the heatsink is used to cool the busbar, then the structure is simple, but the cooling efficiency is insufficient
Solution Approach 1:
The heatsink configuration is expanded from single-face to two-face cooling architecture. By utilizing both opposite faces of the heatsink for busbar contact, the patent doubles the effective cooling surface area, significantly improving heat dissipation efficiency without requiring multiple separate heatsink components.
3Ease of manufacture
If the busbar is made from a single piece surrounding the heatsink, then manufacturing is simplified, but assembly precision requirements increase
Solution Approach 1:
The busbar is designed as a single integrated piece that surrounds the heatsink, merging the electrical conductor function with the structural housing function. This integration simplifies manufacturing by eliminating the need for multiple busbar segments and their associated connections, while the surrounding geometry naturally provides alignment features that reduce assembly precision requirements.
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
This configuration enhances heat dissipation for the busbar, reducing the risk of damage from heat and allowing for easier manufacturing and assembly, while also providing additional cooling for other components.
Implementation Method 1
the busbar comes against said two opposite faces of the heatsink in such a way as to be cooled by the heatsink
Implementation Method 2
a cooling box provided with a system for circulating a cooling liquid
Data Source
AI summary
The invention relates to electrical equipment comprising:a heatsink comprising an internal volume delimited by at least two opposite faces,a busbar,said busbar coming against said two opposite faces of the heatsink in such a way as to be cooled by said heatsink.