Electrical assembly
An assembly includes an electrical component; a bus bar assembly connected with the electrical component; and a cooling member connected with the bus bar assembly, the cooling member including: a tubular member; and a cover enclosing portions of the tubular member, the cover comprising thermally conductive and electrically insulating material. The enclosed portions of the tubular member may include a non-circular cross-section.
1 . An assembly, comprising:
an electrical component;
a bus bar assembly connected with the electrical component; and
a cooling member connected with the bus bar assembly, the cooling member comprising:
a tubular member; and
a cover configured to enclose a portion of the tubular member, wherein the cover is overmolded on the tubular member, such that at least a portion of the overmolded cover is disposed between external ribs of the tubular member, and wherein the cover comprising thermally conductive and electrically insulating material.
2 . The assembly of claim 1 , wherein the portion of the tubular member enclosed by the cover include a non-circular cross-section.
3 . The assembly of claim 2 , wherein the portion of the tubular member that is enclosed by the cover include planar top and bottom surfaces and curved or rounded side surfaces.
4 . The assembly of claim 1 , wherein the tubular member includes at least one of a plurality of inner channels and surface features that increase contact between a coolant and the tubular member.
5 . The assembly of claim 1 , wherein the tubular member includes a first adapter connected to a first end of the tubular member and a second adapter connected to a second end of the tubular member.
6 . The assembly of claim 1 , wherein the tubular member includes a plurality of external ribs to facilitate connection with the cover.
7 . The assembly of claim 1 , wherein the tubular member includes one or more flanges.
8 . The assembly of claim 1 , wherein the cover is in direct contact with the bus bar assembly and the cooling member.
9 . The assembly of claim 1 , wherein the bus bar assembly is configured for use with electrical currents of at least 200 Amps.
10 . The assembly of claim 1 , wherein the bus bar assembly includes a plurality of pairs of bus bars disposed directly on the cover in an end-to-end configuration.
11 . The assembly of claim 10 , wherein the electrical component includes: a first contactor that is electrically connected to a first pair of bus bars of the plurality of pairs of bus bars; and a second contactor that is electrically connected to a second pair of bus bars of the plurality of pairs of bus bars.
12 . The assembly of claim 1 , wherein the bus bar assembly includes a first bus bar disposed on a top surface of the cover and a second bus bar disposed on a bottom surface of the cover.
13 . A vehicle including the assembly of claim 1 .
14 . The assembly of claim 1 , wherein the portion of the tubular member enclosed by the cover is U-shaped.
15 . The assembly of claim 1 , wherein the portion of the tubular member enclosed by the cover is serpentine shaped.
16 . The assembly of claim 1 , wherein the cover comprises one or more expansion joints, the joints compensating for a difference in thermal expansion between the tubular member and the cover.
17 . The assembly of claim 5 , wherein each of the first adaptor and the second adaptor comprises one or more internal fins, the fins directing a flow of a coolant through the tubular member.
18 . The assembly of claim 1 , wherein the assembly further comprises a zinc coating disposed over the tubular member forming a bond between the tubular member and the cover.
19 . The assembly of claim 1 , wherein a height of the external ribs is less than 10% of a height of the tubular member.