Flexible busbar

Abstract

A busbar for an automobile includes a first rigid section and a second rigid section, each of the first rigid section and the second rigid section is made of a first conductive metal material and has a first effective cross-sectional area, and includes a flexible section located between the first rigid section and the second rigid section and interconnecting the first rigid section and the second rigid section, the flexible section is made of a second conductive metal material, has a second effective cross-sectional area and includes a top surface and a bottom surface, at least one of the top surface and the bottom surface includes a plurality of pores formed therein and spaced apart along the flexible section, wherein the second effective cross-sectional area is smaller than the first effective cross-sectional area, and the conductivity of the second conductive material is higher than that of the first conductive material.

Description

Technical Field

[0001] The present disclosure relates to a bus bar for an automobile, and more particularly, to a bus bar having a flexible section for an automobile. Background Art

[0002] A busbar is an electrical conductor suitable for connecting multiple electrical outputs to a common power source within a vehicle. A key strategy for the global automotive industry is to design vehicles with advanced power capabilities. The design of enhanced electronic and sensor capabilities throughout the vehicle is driven not only by consumer preferences and fierce competition, but also by the requirements for comfort, convenience, safety, and environmental protection.

[0003] In recent years, the demand for these increased electrical uses has been driven by the development of hybrid or electric vehicles. Just a few years ago, the electrical power requirements of a typical car might be around 1kW. Currently, the power requirements of automotive electrical systems are around 3kW. In comparison, the average power of a hybrid vehicle is 30kW and the average power of a pure electric vehicle is 50kW.

[0004] Given the insatiable demand for power in electric vehicles, the way the vehicle's electrical architecture is assembled becomes critical to the vehicle's safety and performance. Busbars help remove high voltage electricity from the battery and deliver it to various locations in the vehicle where power is needed. Compared to power cables, busbars enable high power density power distribution. The material composition and cross-sectional dimensions of the busbar determine the maximum amount of current it can safely carry. Therefore, as the power demand in the car increases, the size of the vehicle's busbars also increases. In addition, the busbar must have enough rigidity to support its own weight and the forces applied by mechanical vibrations.

[0005] As battery technology improves and the range of electric vehicles (EVs) and hybrid electric vehicles (HEVs) increases, interest in these vehicles is growing steadily. Perhaps just as important, EVs / HEVs offer a "green" alternative to vehicles powered by traditional gasoline internal combustion engines. The bus in an EV / HEV is primarily responsible for transferring electrical energy from a large, high-power battery pack to an inverter for conversion into AC power for use by the electric engine.

[0006] As the size of automotive busbars increases, their installation inside the vehicle becomes an issue. Inside the vehicle, components are tightly packed, leaving little extra space to conveniently install the busbar. One installation solution is to bend or fold the busbar into a more compact shape to insert into the vehicle's interior space. Once in the proper position, the busbar is unfolded and bent back to the proper shape and secured in place. However, since the busbar is made of a rigid metal material, any bending or deformation of the busbar will cause it to plastically deform, resulting in an undesirable profile when the busbar is bent back to the proper shape. Any deviation in shape from its proper shape will result in the busbar not being accurately installed in the intended space.

[0007] Therefore, although the existing automotive busbars have achieved their intended purpose, there is still a need for a new and improved busbar that includes a flexible section so that the busbar can be folded into a more compact shape for insertion into the interior space of the vehicle and can be unfolded to its proper shape to be fixed in place in the vehicle. Summary of the invention

[0008] According to several aspects of the present disclosure, an automobile busbar includes a first rigid section and a second rigid section, each of the first rigid section and the second rigid section is made of a first conductive metal material and has a first effective cross-sectional area, and includes a flexible section located between the first rigid section and the second rigid section and interconnecting the first rigid section and the second rigid section, the flexible section is made of a second conductive metal material and has a second effective cross-sectional area, a top surface and a bottom surface, at least one of the top surface and the bottom surface includes a plurality of pores formed therein and spaced apart along the flexible section, wherein the second effective cross-sectional area is smaller than the first effective cross-sectional area, and the conductivity of the second conductive material is higher than that of the first conductive material.

[0009] According to another aspect of the present disclosure, the flexible segment includes one of a single-sided notched profile and a double-sided notched profile.

[0010] According to another aspect of the present disclosure, the flexible segment includes one of a square waveform profile, a triangular waveform profile, and a sinusoidal waveform profile.

[0011] According to another aspect of the present disclosure, the busbar further includes a flexible insulating coating encapsulating the flexible section and filling the pores formed therein.

[0012] According to another aspect of the present disclosure, the flexible insulating coating has a portion adjacent to one of the top surface and the bottom surface, the portion having a thickness greater than a thickness of a corresponding portion adjacent to the other of the top surface and the bottom surface.

[0013] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The drawings described herein are only for illustrative purposes of the present disclosure and are not intended to limit the scope of the present disclosure in any way.

[0015] Figure 1 is a perspective view of a portion of a busbar of an automobile according to an exemplary embodiment;

[0016] Figure 2 is along Figure 1 A cross-sectional view taken along line 2-2 in FIG.

[0017] Figure 3A Yes Figure 1 a perspective view of the portion of the automotive busbar shown without the flexible coating, wherein the flexible segment includes a square wave profile;

[0018] Figure 3B is along Figure 3A A cross-sectional view taken along line 3B-3B in FIG.

[0019] Figure 3C is along Figure 3A A cross-sectional view taken along line 3C-3C in FIG.

[0020] Figure 4 is a side view of an automobile busbar, wherein the flexible section includes a single-sided notched profile;

[0021] Figure 5 is a side view of an automobile busbar, wherein the flexible section includes a double-sided notched profile;

[0022] Figure 6 is a side view of a busbar of an automobile, wherein the flexible section comprises a triangular waveform profile;

[0023] Figure 7 is a side view of a busbar of an automobile, wherein the flexible section comprises a sinusoidal waveform profile;

[0024] Figure 8 yes Figure 2 The enlarged part, in Figure 2 Marked as " Figure 8 ";as well as

[0025] Fig. 9 yes Figure 8 The enlarged part, in Figure 8 Marked as " Fig. 9 ”. DETAILED DESCRIPTION

[0026] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0027] refer to Figure 1The automobile busbar 10 according to the present disclosure includes a first rigid section 12, a second rigid section 14, and a flexible section 16 located between the first rigid section 12 and the second rigid section 14 and interconnecting the first rigid section 12 and the second rigid section 14. The flexible section 16 is adapted to fold the busbar 10 into a more compact shape for insertion into an interior space of an automobile. Once the busbar 10 is positioned in a space within the automobile, the flexible section 16 is adapted to unfold the busbar 10 back to its proper shape to be fixed in place within the automobile.

[0028] The busbar 10 is an electrical conductor suitable for connecting a plurality of electrical outputs to a common power source in a vehicle. Therefore, the first rigid section 12, the second rigid section 14 and the flexible section 16 are all made of conductive metal materials.

[0029] The flexible section 16 is adapted to allow the busbar 10 to be bent or folded and to facilitate bending / folding of the busbar 10 thereat. In addition, the flexible section 16 is also adapted to allow the busbar 10 to be unfolded or bent back to its original shape without creating any undesirable profile different from the original shape of the busbar 10. Figure 2 and Figure 3A In the exemplary embodiment, the flexible segment 16 includes a top surface 18 and a bottom surface 20. At least one of the top surface 18 and the bottom surface 20 includes a plurality of apertures 22 formed therein and spaced apart along the flexible segment 16. Figure 3B and Figure 3C , the pores 22 reduce the effective cross-sectional area 23 of the flexible segment 16, so the effective cross-sectional area 23 of the flexible segment 16 is smaller than the effective cross-sectional area 25 of the first rigid segment 12 and the second rigid segment 14. Since the effective cross-sectional area 23 of the flexible segment 16 is smaller than the effective cross-sectional area 25 of the first rigid segment 12 and the second rigid segment 14, the flexible segment 16 is weaker than the first rigid segment 12 and the second rigid segment 14, and the bending of the busbar 10 mainly occurs in the flexible segment 16.

[0030] Furthermore, the apertures 22 allow the busbar 10 to be bent within the flexible section 16 with relatively small plastic deformations, as compared to the plastic deformations that would be produced by bending the larger cross-sections of the first and second rigid sections 12, 14. This allows the flexible section 16 to be unfolded or bent back to its original shape with little or no undesirable contouring.

[0031] In order to properly function as a busbar, the flexible segment 16 must conduct current at least as efficiently as the first rigid segment 12 and the second rigid segment 14. Since the effective cross-sectional area 23 of the flexible segment 16 is smaller than the effective cross-sectional area of ​​the first rigid segment 12 and the second rigid segment 14, the flexible segment 16 must be made of a different material from the first rigid segment 12 and the second rigid segment 14. If the flexible segment 16 and the first rigid segment 12 and the second rigid segment 14 are made of the same material, the current path is reduced due to the reduction in the effective cross-sectional area 23 of the flexible segment 16, resulting in heat accumulation in the flexible segment 16. Therefore, in an exemplary embodiment, the first rigid segment 12 and the second rigid segment 14 are made of a first conductive metal material, and the flexible segment 16 is made of a second conductive metal material. The conductivity of the second conductive material is higher than that of the first conductive material.

[0032] Electrical conductivity, or conductivity, is a measure of a material's ability to conduct electricity. The conductivity of a metal is the result of the movement of electrically charged particles. Atoms of metallic elements are characterized by the presence of valence electrons, which are electrons in the outermost shell of the atom that are free to move. It is these "free electrons" that allow metals to conduct electrical current. Because valence electrons are free to move, they can move through the crystal lattice that makes up the metal's physical structure. Energy transfer is strongest when there is little resistance. Likewise, the most efficient conductors of electricity are metals that have a single valence electron that is free to move and strongly repels other electrons. This is also true of the most conductive metals, such as silver, gold, and copper. Every metal has a single valence electron that has little resistance to movement and strongly repels other electrons.

[0033] Therefore, in order to offset the fact that the flexible section 16 has a smaller effective cross-sectional area 23, the flexible section 16 must be made of a material having a higher electrical conductivity than the first rigid section 12 and the second rigid section 14. In an exemplary embodiment, the first rigid section 12 and the second rigid section 14 are made of aluminum and the flexible section 16 is made of copper. The electrical conductivity of copper is approximately twice that of aluminum, so that the current conducted by the busbar 10 through the first rigid section 12 and the second rigid section 14 is almost equal to the current conducted through the flexible section 16.

[0034] Reference again Figure 2 3, as previously described, the flexible segment 16 includes a top surface 18 and a bottom surface 20. At least one of the top surface 18 and the bottom surface 20 includes a plurality of apertures 22 formed therein and spaced apart along the flexible segment 16. Figure 2 As shown in FIG. 3 , in one exemplary embodiment, the flexible section 16 includes a square wave profile. Figure 4 In another exemplary embodiment, the flexible section 16 includes a single-sided notched profile. Figure 5 In another exemplary embodiment, the flexible section 16 includes a double-sided notched profile. Figure 6In another exemplary embodiment, the flexible section 16 includes a triangular wave profile. Figure 7 In another exemplary embodiment, the flexible section 16 includes a sinusoidal waveform profile.

[0035] Reference again Figure 1 and Figure 2 The busbar 10 also includes a flexible insulating coating 24 that encapsulates the flexible section 16 and fills the pores formed therein. The busbar 10 also includes a similar flexible insulating coating 26 located on the first rigid section 12 and the second rigid section 14.

[0036] The flexible insulating coatings 24, 26 on the first rigid section 12, the second rigid section 14 and the flexible section 16 are used to prevent the busbar 10 from short-circuiting due to contact with the conductive outer surface inside the vehicle, thereby ensuring proper power transmission through the busbar 10. The flexible insulating coatings 24, 26 on the first rigid section 12, the second rigid section 14 and the flexible section 16 can also be used as dampers to absorb vibrations to which the busbar 10 is subjected during the operation of the vehicle.

[0037] refer to Figure 8 In one exemplary embodiment, the flexible insulating coating 24 of the flexible segment 16 has a first portion 28 adjacent to one of the top surface 18 and the bottom surface 20, the first portion 28 being thicker than a corresponding second portion 30 adjacent to the other of the top surface 18 and the bottom surface 20. Figure 8 As shown, a first portion 28 of the flexible insulating coating 24 adjacent to the top surface 18 of the flexible segment 16 has a first thickness 32, and a second portion 30 of the flexible insulating coating 24 adjacent to the bottom surface 20 of the flexible segment 16 has a second thickness 34, which is less than the first thickness 32. This will promote bending of the flexible segment 16 in one direction while providing resistance to bending of the flexible segment 16 in the opposite direction. The thicker first portion 28 of the flexible insulating coating 24 of the flexible segment 16 adjacent to the top surface 18 provides resistance to bending of the flexible segment 16 upward. The thinner second portion 30 of the flexible insulating coating 24 of the flexible segment 16 adjacent to the bottom surface 20 will encourage the flexible segment 16 to bend downward, as shown. Fig. 9 As shown by arrow 36.

[0038] The flexible insulating coating 24 of the flexible segment 16 can be made of any suitable material having appropriate insulating, damping and compliance properties. In an exemplary embodiment, the flexible insulating coating 24 of the flexible segment 16 is a unitary piece of elastomeric material, such as but not limited to TPE or EPDM. The flexible insulating coating 24 can be molded directly onto the flexible segment 16 or molded to match the contour of the flexible segment 16 and placed thereon. The flexible insulating coating 24 of the flexible segment 16 also provides structural support to the flexible segment 16 of the busbar 10 and helps allow the flexible segment 16 to bend or fold and then straighten / unfold to its original shape. Reference Fig. 9 When the flexible segment 16 is bent (as shown by arrow 36), the flexible insulating coating 24 within the pores 22 adjacent to the top surface 18 is stretched (as shown by arrow 38), and the flexible insulating coating 24 within the pores 22 adjacent to the bottom surface 20 is compressed (as shown by arrow 40).

[0039] The flexible insulating coating 24 on the flexible segment 16 of the busbar 10 can provide structural support to help ensure that the busbar 10 maintains its shape and prevent the flexible segment 16 from accidentally bending. When sufficient force is applied to intentionally bend the flexible segment 16 of the busbar 10, energy is absorbed by the flexible insulating coating 24 that is stretched and compressed in the pores 22 of the flexible segment 16. This energy is stored in the flexible insulating coating 24 until the busbar 10 bends / unfolds back to its original shape. The energy stored in the flexible insulating coating 24 helps facilitate the bending of the flexible segment 16 back to its original shape without creating any undesirable contours. The material used for the flexible insulating coating 24 of the flexible segment 16 can be selected to provide a calibrated bending strength.

[0040] The busbar 10 of the present disclosure has several advantages. The most prominent advantage is that the busbar 10 of the present disclosure can be folded into a more compact shape to be inserted into a space inside a car, and can be unfolded back to its proper shape to be fixed in place in the car without creating any undesirable contours.

[0041] The description of the present disclosure is merely exemplary in nature, and variations that do not depart from the gist of the present disclosure are intended to fall within the scope of the present disclosure. Such variations should not be regarded as departing from the spirit and scope of the present disclosure.

Claims

1. An automobile busbar, comprising: a first rigid section, the first rigid section being made of a first conductive metal material; a second rigid section, the second rigid section being made of the first conductive metal material; and a flexible segment located between the first rigid segment and the second rigid segment and connecting the first rigid segment and the second rigid segment to each other, the flexible segment being made of a second conductive metal material; The electrical conductivity of the second conductive metal material is higher than that of the first conductive metal material.

2. The busbar of claim 1, wherein the flexible segment includes a top surface and a bottom surface, at least one of the top surface and the bottom surface including a plurality of apertures formed therein and spaced apart along the flexible segment. 3 . The busbar of claim 2 , wherein the flexible segment comprises an effective cross-sectional area that is smaller than effective cross-sectional areas of the first and second rigid segments. 4 . The busbar according to claim 3 , wherein the first rigid section and the second rigid section are made of aluminum, and the flexible section is made of copper. The busbar of claim 3 , wherein the flexible section comprises a single-sided notched profile. The busbar of claim 3 , wherein the flexible segment comprises a double-sided notched profile. The busbar of claim 3 , wherein the flexible segment comprises a corrugated profile.

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