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CN-122000795-A - Power distribution module with cooling busbar

CN122000795ACN 122000795 ACN122000795 ACN 122000795ACN-122000795-A

Abstract

An electrical power distribution module having a cooling bus bar including a housing and a bus bar disposed within the housing, the bus bar having a first end connected to an input conductor extending out of the housing and a second end connected to an electrical device located within the housing, the bus bar having a cooling conduit extending therethrough, wherein the first end of the cooling conduit is connected to the cooling device by a cooling line, and wherein the second end of the cooling conduit is connected to a drain port of the housing by a drain line.

Inventors

  • CHENG DU
  • PAN SHANGCHUN

Assignees

  • 苏州力特奥维斯保险丝有限公司

Dates

Publication Date
20260508
Application Date
20241106

Claims (17)

  1. 1. A Power Distribution Module (PDM) comprising: A housing, and A busbar disposed within the housing, the busbar having a first end connected to an input conductor extending out of the housing and a second end connected to an electrical device located within the housing, the busbar having a cooling conduit extending therethrough; Wherein a first end of the cooling conduit is connected to a cooling device by a cooling line, and wherein a second end of the cooling conduit is connected to a discharge port of the housing by a discharge line.
  2. 2. The PDM of claim 1, wherein the cooling device is located inside the housing.
  3. 3. The PDM of claim 1, wherein the cooling device is located outside of the housing.
  4. 4. The PDM of claim 1, wherein the cooling device is an electric fan.
  5. 5. The PDM of claim 1, wherein the electrical device is a primary electrical device, the PDM further comprising a secondary electrical device connected to the busbar.
  6. 6. The PDM of claim 1, wherein the cooling conduit comprises a plurality of cooling conduits extending through the busbar, and wherein the drain port comprises a plurality of drain ports, the plurality of cooling conduits being connected to the cooling device by a plurality of respective cooling lines and to the plurality of drain ports by a plurality of respective drain lines.
  7. 7. The PDM of claim 1, wherein the electrical device is a contactor having an input connected to the second end of the busbar.
  8. 8. The PDM of claim 7, wherein the busbar is a first busbar, and wherein the contactor has an output connected to a second busbar located within the housing.
  9. 9. The PDM of claim 8, wherein the electrical device is a primary electrical device, the PDM further comprising a secondary electrical device connected to the first busbar and a tertiary electrical device connected to the second busbar.
  10. 10. The PDM of claim 7, wherein the contactor includes a control line connected to a low voltage power supply located outside the housing, and wherein the cooling device is also connected to the low voltage power supply.
  11. 11. A Power Distribution Module (PDM) comprising: A housing; a first busbar disposed within the housing, the first busbar having a first end connected to an input conductor extending out of the housing and a second end connected to an input of a primary electrical device located within the housing, the first busbar having a cooling conduit extending therethrough, wherein the first end of the cooling conduit is connected to a cooling device by a cooling line, and wherein the second end of the cooling conduit is connected to a drain port of the housing by a drain line; a second busbar disposed within the housing and connected to an output of the primary electrical device; a secondary electrical device connected to the first busbar, and And a three-stage electrical device connected to the second busbar.
  12. 12. The PDM of claim 11, wherein the cooling device is located inside the housing.
  13. 13. The PDM of claim 11, wherein the cooling device is located outside of the housing.
  14. 14. The PDM of claim 11, wherein the cooling device is an electric fan.
  15. 15. The PDM of claim 11, wherein the cooling conduit includes a plurality of cooling conduits extending through the first busbar, and wherein the drain port includes a plurality of drain ports, the plurality of cooling conduits being connected to the cooling device by a plurality of respective cooling lines and to the plurality of drain ports by a plurality of respective drain lines.
  16. 16. The PDM of claim 11, wherein the electrical device is a contactor.
  17. 17. The PDM of claim 16, wherein the contactor includes a control line connected to a low voltage power supply located outside the housing, and wherein the cooling device is also connected to the low voltage power supply.

Description

Power distribution module with cooling busbar Technical Field The present disclosure relates generally to the field of power distribution devices, and more particularly to power distribution modules having active cooling busbar. Background A power distribution module (sometimes referred to as a "power distribution unit") in an Electric Vehicle (EV) is a key component that distributes electrical power from a main battery of the vehicle to various subsystems, such as a motor, a charger, and an auxiliary system. The Power Distribution Module (PDM) acts as a central hub for power routing, voltage regulation and protection through circuit breakers, relays and fuses. PDMs facilitate safe and efficient delivery of power to critical components while also managing the high voltages and currents common in EV systems. The busbar in PDM is a metal strip or bar that acts as a conductor to carry a large amount of current. Bus bars, typically made of copper or aluminum, provide a low resistance path for the current and help organize the distribution of electrical energy to the various circuits connected to the bus bars in the vehicle. The high currents required for operation of EVs can generate significant amounts of heat in the busbar. If not managed properly, excessive heat in the busbar can cause several problems: Resistance increases-as the temperature of the busbar increases, the resistance of the conductive material of the busbar also increases. This further exacerbates the thermal problem in the cycle known as "thermal runaway", resulting in more heat generation and reduced power transfer efficiency. Material degradation-over time, high temperatures may degrade busbar material, especially at joints and junctions. This may lead to oxidation, corrosion or softening of the material, especially if the busbar is made of aluminium. Insulation damage-excessive heat may damage the insulation around the bus bar, causing short circuits, reduced electrical performance, or arcing between components, causing serious safety risks. Thermal expansion—as the busbar heats up, the busbar expands, which may result in mechanical stress or loose connections on the mounting structure and components. These loose connections in turn may increase resistance, causing further heat generation. Thermal stresses on surrounding components-the heat generated by the busbar may also affect nearby components in the PDM, such as relays, capacitors, and semiconductors. This may lead to premature failure or performance degradation of these components, reducing the overall reliability of the EV's electrical system. It is with respect to these considerations and others that the improvements of the present invention may be useful. Disclosure of Invention This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. A power distribution module according to an embodiment of the present disclosure may include a housing and a bus bar disposed within the housing, the bus bar having a first end connected to an input conductor extending out of the housing and a second end connected to an electrical device located within the housing, the bus bar having a cooling conduit extending therethrough, wherein the first end of the cooling conduit is connected to the cooling device by a cooling line, and wherein the second end of the cooling conduit is connected to a drain port of the housing by a drain line. Another power distribution module according to an embodiment of the present disclosure may include a housing, a first busbar disposed within the housing having a first end connected to an input conductor extending out of the housing and a second end connected to an input of a primary electrical device located within the housing, the first busbar having a cooling conduit extending therethrough, wherein the first end of the cooling conduit is connected to the cooling device by a cooling line, and wherein the second end of the cooling conduit is connected to a drain port of the housing by a drain line. The power distribution module may further include a second busbar disposed within the housing and connected to an output of the primary electrical device, a secondary electrical device connected to the first busbar, and a tertiary electrical device connected to the second busbar. Drawings Fig. 1A is a top view illustrating a power distribution module according to an embodiment of the present disclosure; FIG. 1B is a partial perspective view showing the power distribution module of FIG. 1A, and Fig. 2 is a detailed view illustrating a bus bar of the power distribution module of fig. 1A. The figures are not necessarily drawn to scale. The drawings are merely schematic representations, not intend