Vertical Input Bus Bar Layout for Compact Power Control Cooling
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Solution Overview
Problem
Existing power control units for electric vehicles face challenges in minimizing size while effectively cooling power devices, as plate-shaped bus bars require significant space and can inadequately dissipate heat when positioned away from coolers, leading to heat transfer issues.
Innovation Solution
The power control unit incorporates plate-shaped bus bars with one end connected to power devices, where input bus bars are erected perpendicular to the heat dissipation member with an insulating resin interposed, reducing the installation area and enhancing heat absorption by the dissipation member, thus minimizing unit size and preventing heat transfer to external components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the bus bar is disposed away from the upper area of the cooler, then the cooler size and power control unit size are reduced, but the cooling of the bus bar becomes insufficient and heat transfer to other circuit elements occurs
Solution Approach 1:
The bus bar is changed from a horizontal plate shape to a vertical plate shape, utilizing the vertical dimension above the power device. This dimensional change allows the bus bar to be positioned close to the cooler for effective cooling while minimizing the horizontal footprint area, thus reducing the overall cooler and power control unit size without compromising cooling performance.
2Temperature
If a plate-shaped bus bar is disposed with front and back surfaces facing vertical direction, then the bus bar can be cooled by the cooler, but a large space is required in plan view
Solution Approach 1:
The bus bar is oriented vertically with its front and back surfaces facing the vertical direction, utilizing the height dimension rather than horizontal space. This allows the bus bar to be effectively cooled by the cooler while minimizing the plan view area occupied, thus resolving the contradiction between cooling effectiveness and compact footprint.
Solution Approach 2:
The vertical plate-shaped bus bar is nested in the vertical space above the power device, utilizing the available height dimension. This nesting approach allows the bus bar to be positioned within the existing vertical envelope of the power control unit, achieving effective cooling without increasing the horizontal footprint area.
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 effectively absorbs heat from power devices, reduces the size of the power control unit, and prevents heat from being dissipated to other circuit elements, achieving efficient cooling and miniaturization.
Implementation Method 1
a heat dissipation member disposed to face the power device with an insulating resin member interposed therebetween
Implementation Method 2
an insulating resin member interposed therebetween
Data Source
AI summary
A power control unit includes a power device, a heat dissipation member disposed to face the power device with an insulating resin member interposed therebetween, and a plurality of plate-shaped bus bars each of which has one end connected to the power device, in which a plurality of input bus bars connected to an input terminal of the power device are provided as the bus bar, and at least one of the plurality of input bus bars is erected so that a direction along a plate width is aligned with a direction along a normal line of a surface of the heat dissipation member facing the power device, and is disposed with respect to the heat dissipation member with the insulating resin member interposed therebetween.