High voltage laminated power distribution system with integrated fuses

Patent metadata

Field	Value
Publication number	US-12407155-B2
Application number	US-202318199167-A
Country	US
Kind code	B2
Filing date	May 18, 2023
Priority date	Nov 13, 2018
Publication date	Sep 2, 2025
Grant date	Sep 2, 2025

Abstract

A high voltage distribution system is provided with multiple fuses. The high voltage distribution system includes multiple laminated busbars that are electrically coupled to a battery and to the multiple fuses. Busbars are electrically coupled to the one or more fuses via electrical connections between the busbars and the fuses. The electrical connections can pass through other busbars without having an electrical coupling to the other busbars. An insulating layer may be used between the busbars to prevent overcurrent events. The configuration, size, and position of each busbar is selected based on the electrical requirements of components that are electrically coupled to the busbar and based on the prevention of overcurrent events.

First claim

What is claimed is:

1. A system comprising:
a first busbar and a second busbar; and
an electrically conductive interconnect, wherein:
the electrically conductive interconnect is electrically coupled to the first busbar and passes through the second busbar without an electrical coupling to the second busbar; and
the electrically conductive interconnect is insulated.

2. The system of claim 1 , further comprising an insulator located between the first busbar and the second busbar, wherein the electrically conductive interconnect passes through the insulator.

3. The system of claim 1 , further comprising a fuse, wherein the first busbar is electrically coupled to the fuse via the electrically conductive interconnect.

4. The system of claim 1 , wherein the first busbar, the second busbar, and the electrically conductive interconnect are located within a battery enclosure.

5. The system of claim 1 , wherein the first busbar is located within a first electrically conductive layer, and wherein the second busbar is located within a second electrically conductive layer, and wherein the electrically conductive interconnect passes vertically from the first electrically conductive layer through the second electrically conductive layer.

6. The system of claim 1 , further comprising an electrically conductive pad, wherein:
the electrically conductive pad is located above the second busbar; and
the electrically conductive pad is electrically coupled to the electrically conductive interconnect.

7. A vehicle comprising:
a battery enclosure comprising:
a first busbar and a second busbar; and
an electrically conductive interconnect, wherein:
the electrically conductive interconnect is electrically coupled to the first busbar and passes through the second busbar without an electrical coupling to the second busbar; and
the electrically conductive interconnect is insulated.

8. The vehicle of claim 7 , further comprising an insulator located between the first busbar and the second busbar, wherein the electrically conductive interconnect passes through the insulator.

9. The vehicle of claim 7 , further comprising a fuse, wherein the first busbar is electrically coupled to the fuse via the electrically conductive interconnect.

10. The vehicle of claim 7 , wherein:
the battery enclosure further comprises a plurality of batteries electrically coupled to the first busbar and the second busbar; and
the plurality of batteries provide power to an electric motor.

11. The vehicle of claim 7 , wherein the first busbar is located within a first electrically conductive layer, and wherein the second busbar is located within a second electrically conductive layer, and wherein the electrically conductive interconnect passes vertically from the first electrically conductive layer through the second electrically conductive layer.

12. The vehicle of claim 7 , further comprising an electrically conductive pad, wherein:
the electrically conductive pad is located above a surface of the second busbar; and
the electrically conductive pad is electrically coupled to the electrically conductive interconnect.

13. A method of manufacturing comprising:
installing a first busbar, a second busbar, and an electrically conductive interconnect in a battery enclosure wherein:
the electrically conductive interconnect is electrically coupled to the first busbar;
the electrically conductive interconnect passes through the second busbar without an electrical coupling to the second busbar; and
the electrically conductive interconnect is insulated.

14. The method of claim 13 , further comprising:
installing an insulator between the first busbar and the second busbar.

15. The method of claim 13 , further comprising:
electrically coupling a fuse to the electrically conductive vertical interconnect.

16. The method of claim 13 , further comprising:
electrically coupling an electrically conductive pad to the electrically conductive interconnect.

17. The method of claim 13 , wherein the first busbar is installed in a first electrically conductive layer, and wherein the second busbar is installed in a second electrically conductive layer, and wherein the electrically conductive interconnect is installed vertically from the first electrically conductive layer through the second electrically conductive layer.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Baseri Ehsan
• Butterfield Kyle
• O'Neil Kyle
• Collins Tyler
• Wynn Nathaniel C

Classifications

• H01M50/588

  outside the batteries, e.g. incorrect connections of terminals or busbars · CPC title

• H01M50/583

  in response to current, e.g. fuses · CPC title

• H01M50/505

  comprising a single busbar · CPC title

• H01M50/526

  having a layered structure · CPC title

• H01M50/524

  Organic material · CPC title