Power distribution device with a thermal component

Patent metadata

Field	Value
Publication number	US-12555992-B2
Application number	US-202217882990-A
Country	US
Kind code	B2
Filing date	Aug 8, 2022
Priority date	Aug 8, 2022
Publication date	Feb 17, 2026
Grant date	Feb 17, 2026

Abstract

A power distribution device with an electric component is provided. The device can include a busbar. The device can include a thermal component coupled to the busbar to dissipate heat generated at the busbar. The device can include a material molded over at least a portion of the thermal component to electrically isolate at least the portion of the thermal component from the busbar.

First claim

What is claimed is:

1 . A device, comprising:
a first busbar; a thermal component coupled to the first busbar to dissipate heat generated at the first busbar; and a material molded over at least one portion of the thermal component to electrically isolate the at least one portion of the thermal component from the first busbar, the thermal component over-molded with the material forming a lateral portion that forms a portion of a first lateral wall of a housing, the thermal component comprising a coolant channel formed by the first lateral wall of the housing.

2 . The device of claim 1 , comprising:
the first busbar to transfer power from a battery; and the thermal component to dissipate the heat generated at the first busbar based at least on the power transferred from the battery.

3 . The device of claim 1 , comprising:
the thermal component comprising:
an inlet to receive coolant that dissipates the heat generated at the first busbar; and
an outlet to pass the coolant out of the thermal component.

4 . The device of claim 1 , comprising:
the housing comprising the first lateral wall; and the lateral portion forming the portion of the first lateral wall coupled to the first busbar.

5 . The device of claim 1 , comprising:
the lateral portion comprising:
the material molded over at least the portion of the thermal component, the material molded over an outer side of the thermal component interfacing with the first busbar to support the first busbar.

6 . The device of claim 1 , comprising:
the lateral portion comprising:
the thermal component;
the material molded over at least a portion of an outer side of the thermal component; and
wherein the material molded over at least the portion of the outer side of the thermal component forms an outer surface of the first lateral wall of the housing of the device to support the lateral portion.

7 . The device of claim 1 , comprising:
a lateral portion comprising:
the thermal component;
the material; and
at least one leg mounted to an outer surface of the material molded over the thermal component, the at least one leg configured to connect to an outer surface of a lateral wall of a housing of the device.

8 . The device of claim 1 , comprising:
a second busbar to electrically connect the device to a component of a system; the thermal component disposed between the first busbar and the second busbar and disposed within the first lateral wall of the housing; and the thermal component interfacing with at least a portion of the first busbar to dissipate the heat generated at the first busbar.

9 . The device of claim 1 , comprising:
the lateral portion comprising:
the thermal component;
the material;
a first portion of the lateral portion interfacing with the first busbar and forming the first lateral wall of housing of the device; and
a second portion of the lateral portion interfacing with a second busbar and forming a second lateral wall of the housing to cool the second busbar.

10 . The device of claim 1 , comprising:
the lateral portion comprising:
a first portion of the lateral portion interfacing with the first busbar and forming the first lateral wall of the housing of the device, the first portion of the lateral portion comprising a first portion of the thermal component to cool the first busbar;
a second portion of the lateral portion interfacing with a second busbar of the device and forming a second lateral wall of the housing, the second portion of the lateral portion comprising a second portion of the thermal component to cool the second busbar; and
a third portion of the lateral portion that is curved and positioned between the first portion of the lateral portion and the second portion of the lateral portion, the third portion of the lateral portion comprising a third portion of the thermal component that is curved and transports coolant between the first portion of the thermal component and the second portion of the thermal component.

11 . The device of claim 1 , the thermal component comprising:
an inlet to receive coolant from a first line of a system that transports the coolant to the thermal component; and an outlet to provide the coolant from the thermal component to a second line of the system that transports the coolant.

12 . The device of claim 1 , the thermal component comprising:
an inlet to receive coolant from a line of a vehicle that transports the coolant from a second thermal component of the vehicle to the thermal component.

13 . The device of claim 1 , the thermal component comprising:
a first lateral wall, a second lateral wall, a third lateral wall, a fourth lateral wall, a top portion, and a bottom portion; and wherein the material is molded over outer surfaces of the first lateral wall, the second lateral wall, the third lateral wall, the fourth lateral wall, the top portion, and the bottom portion.

14 . A method, comprising:
providing a first busbar; providing a thermal component coupled to the first busbar to dissipate heat generated at the first busbar; and providing a material to mold over at least a portion of the thermal component, wherein the material electrically isolates at least the portion of the thermal component from the first busbar, the portion of the thermal component over-molded with the material forming a lateral portion that forms a portion of a first lateral wall of a housing, the thermal component comprising a coolant channel formed by the first lateral wall of the housing.

15 . The method of claim 14 , comprising:
fixing the first busbar to the material molded over a first outer side of the thermal component to support the first busbar; and integrating the material molded over a second outer side of the thermal component to form an outer surface of the first lateral wall of the housing of a device to support the thermal component.

16 . The method of claim 14 , comprising:
receiving, by an inlet of the thermal component, coolant that dissipates the heat generated at the first busbar; and passing, by an outlet of the thermal component, the coolant out of the thermal component.

17 . The method of claim 14 , comprising:
providing the housing comprising the first lateral wall; and providing lateral portion interfacing with the first busbar and forming the first lateral wall of the housing, the lateral portion comprising the thermal component and the material.

18 . A power distribution device, comprising:
a first busbar to convey power between a battery of a vehicle and a component of the vehicle to charge the battery of the vehicle or power a load of the vehicle via the battery of the vehicle; a thermal component coupled to the first busbar to dissipate heat generated at the first busbar; and a material molded over at least a portion of the thermal component to electrically isolate at least the portion of the thermal component from the first busbar, the portion of the thermal component over-molded with the material forming a lateral portion that forms a portion of a first lateral wall of a housing of the power distribution device, the thermal component comprising a coolant channel formed by the first lateral wall of the housing.

19 . The power distribution device of claim 18 , comprising:
the lateral portion comprising:
a first portion interfacing with the first busbar and disposed within the first lateral wall of the housing, the first portion comprising a first portion of the thermal component to cool the first busbar;

Assignees

• Rivian Ip Holdings Llc

Inventors

• Dunn Casey
• Thayer Brandon

Classifications

• B60R16/0238 Primary

  Electrical distribution centers · CPC title

• H02G5/10 Primary

  Cooling · CPC title