Interlocking busbars for vehicles

Abstract

Busbar arrangement (114) for a vehicle (102), the arrangement comprising: a printed circuit board (PCB, 302); a first plate (121a) which is supported on the printed circuit board (302) and is configured to allow a first current to flow in a first direction; a second plate (123) supported on the printed circuit board (302) and comprising a first middle plate (123a) positioned below the first plate (121a) to allow a second current flow in a second direction; and a third plate (121b) supported on the printed circuit board (302) and positioned below the first middle plate (123a) of the second plate (123) to allow the first current flow in the first direction, wherein the positioning of the first plate (121a), the second plate (123) and the third plate (121b) relative to each other forms an interlocking arrangement for the busbar arrangement (114), wherein the second current flowing through the second plate (123) is increased by an effective cross-section of the second plate (123), and wherein the interlocking arrangement reduces a temperature above the second plate (123) when the flux of the second current in the second direction differs from the flux of the first current in the first direction relative to an arrangement in which the second current flows in the same direction as the first current, wherein the interlocking arrangement reduces a parasitic current in the second plate (123) if the flux of the second current in the second direction differs from the flux of the first current in the first direction, and wherein the first plate (121a) comprises a first ramp section (360a) extending below the first plate (121a), and wherein the third plate (121b) comprises a second ramp section (360b) which extends below the third plate (121b) and is axially aligned with the first ramp section (360a).

Description

TECHNICAL AREA

[0001] The aspect disclosed here can generally relate to interlocking busbars in a vehicle. In particular, the aspects disclosed here can generally relate to interlocking busbars used in conjunction with a DC / DC converter in a vehicle or in other vehicle electrification systems that handle high currents at medium to high frequencies. These and other aspects are discussed in more detail below. BACKGROUND

[0002] US 9,966,584 B2 discloses a battery pack that includes a busbar at one end, leaving the other end of the battery pack free for cooling or other arrangements. In a plurality of battery cells, the first terminals of the battery cells are located at the first ends of the battery cells. Portions of the second terminals of the battery cells are located at the first ends of the battery cells. The first ends of the battery cells are in a coplanar arrangement. A plurality of busbars is mounted near the first ends of the battery cells. The busbars are coupled to the first and second terminals of the battery cells at the first ends of the battery cells to connect the battery cells in a series, parallel, or series-parallel configuration.

[0003] US 2017 / 0345799 A1 discloses a power module comprising a first busbar with a first plurality of tabs. Each of the first plurality of tabs is electrically connected to a corresponding conductor from a plurality of conductors arranged on a first side. A second busbar has a second plurality of tabs. Each of the second plurality of tabs is electrically connected to a corresponding conductor from a plurality of conductors arranged on a second side. A third busbar has a third plurality of tabs. At least one tab of the third plurality of tabs is electrically coupled to a corresponding conductor from the plurality of conductors arranged on the first side, and at least one tab of the third plurality of tabs is electrically coupled to a corresponding conductor from the plurality of conductors arranged on the second side.

[0004] US 2018 / 0 286 801 A1 concerns semiconductor structures and, in particular, transistor structures and methods for their manufacture.

[0005] US 3,178,668 A relates to electrical power distribution devices and, in particular, to bus channel structures and plug-in or power take-off units for these structures. TECHNICAL TASK AND SOLUTION OF THE INVENTION

[0006] The technical problem to be solved is to specify a busbar arrangement that is improved compared to the prior art. This problem is solved by a busbar arrangement according to claim 1. SUMMARY

[0007] In at least one embodiment, a busbar assembly for a vehicle is provided. The assembly comprises a printed circuit board (PCB), a first plate, a second plate, and a third plate. The first plate is supported on the printed circuit board and is configured to allow current flow in a first direction. The second plate is supported on the printed circuit board and comprises a first middle plate positioned below the first plate to allow current flow in a second direction. The third plate is supported on the printed circuit board and is positioned below the first middle plate of the second plate to allow current flow in the first direction. The positioning of the first plate, the second plate, and the third plate relative to each other forms an interlocking arrangement for the busbar assembly.The second current flowing through the second plate is increased by an effective cross-section of the second plate, and the interlocking arrangement reduces the temperature across the second plate when the flow of the second current in the second direction differs from the flow of the first current in the first direction, relative to an arrangement where the second current flows in the same direction as the first current. The interlocking arrangement reduces parasitic current in the second plate. The first plate includes a first ramp section extending beneath the first plate. The third plate includes a second ramp section extending beneath the third plate and aligned axially with the first ramp section.

[0008] In at least one other embodiment, which is not within the scope of the claims, a busbar assembly for a vehicle is also provided. The assembly comprises a printed circuit board (PCB), a first plate, a second plate, and a third plate. The first plate is supported on the PCB and is configured to allow current to flow in a first direction. The second plate is supported on the PCB and comprises a spanning first section positioned below the first plate to allow current flow in a second direction. The third plate is supported on the PCB and positioned below the second plate to allow current flow in the first direction. The positioning of the first plate, the second plate, and the third plate relative to each other forms an interlocking arrangement.The interlocking arrangement reduces a parasitic current in the second plate if the flow of the second current in the second direction is different from the flow of the first current in the first direction.

[0009] In at least one other embodiment, which is not within the scope of the claims, a busbar arrangement for a vehicle is also provided. The arrangement comprises a first plate, a second plate, and a third plate. The first plate is configured to allow current to flow in a first direction. The second plate comprises a first section positioned below and adjacent to the first plate to allow current flow in a second direction. The third plate is positioned adjacent to the second plate to allow current flow in the first direction. The interlocking arrangement reduces parasitic current in the second plate when the flow of the second current in the second direction differs from the flow of the first current in the first direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The embodiments of the present disclosure are specifically referred to in the accompanying claims. However, other features of the various embodiments will become clearer and are best understood by referring to the following detailed description in conjunction with the accompanying drawings, in which the following applies: Fig. 1 represents a system comprising a busbar arrangement for a vehicle according to one embodiment; Fig. 2 represents a skin effect of a busbar arrangement; Fig. Figure 3 shows various examples of a near-area effect in busbar arrangement; Fig. Figure 4 shows an example of the near-area effect for the busbar arrangement according to one embodiment; Fig. Figure 5 shows a perspective view of the busbar arrangement according to one embodiment; Fig. Figure 6 shows an exploded view of the busbar arrangement according to one embodiment; Fig. Figure 7 shows a cross-sectional view of the busbar arrangement according to one embodiment; Fig. Figure 8 shows a perspective view of the busbar arrangement according to one embodiment; Fig. Figure 9 shows another perspective view of the busbar arrangement according to one embodiment; Fig. Figure 10 shows another perspective view of the busbar arrangement according to one embodiment; Fig. Figure 11 shows an exploded view of the busbar arrangement from below according to one embodiment; and Fig. Figure 12 shows a cross-sectional view of the busbar arrangement together with a first spacer and a second spacer according to one embodiment. DETAILED DESCRIPTION

[0011] As necessary, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of certain components. Therefore, the detailed structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for instructing a person skilled in the art in the application of the present invention in various ways.

[0012] It is acknowledged that directional terms that may be noted here (for example, "top", "bottom", "inside", "outside", "above", "below", etc.) refer only to the orientation of various components of a busbar arrangement, as illustrated in the accompanying figures. Such terms are provided for the context and understanding of the embodiments disclosed herein.

[0013] A vehicle DC / DC converter can handle current transfer between 200 and 250 amps. The DC / DC converter may include various switches operating within a frequency range of 100–200 kHz. Generally, a transformer is coupled to the DC / DC converter via busbars. These busbars can exhibit various conditions that adversely affect performance, such as skin effect and near-field effect. Skin effect occurs when current flows on a limited area of ​​the busbar in response to medium- or high-frequency cyclic switching. For example, current may flow on an outer portion of the busbar's cross-section but not on an inner portion. Near-field effect can introduce parasitic currents into the busbar assembly, increasing the busbar temperature and potentially causing overheating.For example, a large number of busbars can suffer from severe skinning and near-surface effects, while current flows occur that can reach temperatures too high for electronic circuits located near these busbars. Over-temperature protection devices (elements or components) are configured to respond to a temperature increase and disable the protected device. The monitored temperature may rise due to an increase in the ambient temperature or due to excessive power dissipation in the monitored device. The protection element can then shut down the monitored (protected) device (for example, the protection element can either open the current path or disable the activation control).If the busbars exceed a predetermined temperature, the ambient temperature or the area around the busbars also increases, and the protective devices shut down the protected equipment. Ultimately, the entire electronic system becomes inoperable. Generally, such an increase in ambient temperature due to increased heat generated by the busbars is not expected. It is essential to prevent the entire electronic system from becoming inoperable due to this factor.

[0014] The embodiments presented here generally provide a busbar arrangement comprising several interlocking busbars. Such an arrangement can maximize the overall cross-sectional area of ​​the busbar through which current can flow and also provide for heat dissipation, resulting in minimal resistance losses. Additionally, the disclosed busbar arrangement can also eliminate the potential for an ambient temperature rise to prevent unexpected shutdown of the electronic system. These and other aspects are discussed in more detail below.

[0015] Fig. Figure 1 shows a system 100 comprising a busbar arrangement 114 for a vehicle according to one embodiment. The system 100 generally corresponds to a power converter system (or DC / DC converter) in a vehicle 102 that can convert high voltage (HV) on an HV bus 104 into low voltage (LV) on an LV bus 106. The system 100 can also store the low voltage LV on one or more vehicle batteries 107 in the vehicle 102.

[0016] System 100 comprises a comprehensive array of first switching devices 108a-108n, a resonant circuit 110, a transformer 112, a busbar assembly 114 (or a plurality of busbars 121, 123, 125), and a comprehensive array of second switching devices 116a-116n. Generally, a controller 113 controls the plurality of switching devices 108a-108n so that they are selectively activated and deactivated at a switching frequency, thereby generating an alternating current (AC). The resonant circuit 110 generally provides capacitance or inductance for an output supplied by the plurality of first switching devices 108a-108n. The transformer 112 can reduce the output voltage of the AC-based signal from the resonant circuit 110. In one example, the transformer 112 can be formed from a center-tapped configuration.In one example, the transformer 112 comprises a primary side 115 and a secondary side 117. The secondary side 117 can be formed from two coils providing the contacts (or connections) 119a, 119b, and 119n. The contacts 119a, 119b, and 119n are coupled to the plurality of busbars 121, 123, and 125, respectively. The plurality of busbars 121, 123, and 125 receive the reduced AC-based signal. The controller 113 controls the plurality of secondary switching devices 116a–116n to rectify the reduced AC-based signal into a DC signal (for example, a low-voltage DC signal) for storage on the battery 107 or for direct supply to loads.While System 100 generally represents a one-way flow of energy from the HV bus 104 to the NS bus 106, it is recognized that System 100 can also be adapted to allow energy flow from the NS bus 106 to the HV bus 104, while using the plurality of busbars 121, 123 and 125, as set out here.

[0017] Fig. Figure 2 illustrates a skin effect of a busbar assembly. In general, a busbar assembly (i.e., one or more busbars) can exhibit the skin effect because the plurality of first switching devices 108a–108n are driven by the control unit 113 at a switching frequency. As generally shown in Figure 200, at a lower switching frequency, the current can flow uniformly through the busbar assembly over the entire cross-sectional area of ​​the busbar. However, as generally shown in Figure 202, at medium to higher switching frequencies, current can flow through the busbar at both the top and bottom surfaces. Thus, the current flows through the busbar assembly over a limited area of ​​the busbar, minimizing power (i.e., minimizing the cross-sectional area of ​​the busbar, which allows current to flow through the busbar).

[0018] Fig. Figure 3 shows various examples of a near-area effect in the busbar arrangement. As is usually shown in Figure 204, a cross-section through a first busbar 250 and a second busbar 252 is typically depicted. When current flows through the first busbar 250 and the second busbar 252 in the same direction, the current flows on a top surface 254 of the first busbar 250 and on a bottom surface 256 of the second busbar 252. In the scenario presented in Figure 204, the skin effect concentrates the current on the top surface 254 of the first busbar 250 and on the bottom surface 256 of the second busbar 252. This minimizes the current flow in the first busbar 250 and the second busbar 252, as the current flows in a smaller cross-sectional area of ​​the first busbar 250 and the second busbar 252.

[0019] As generally shown in Figure 206, a cross-sectional view of the first busbar 250 and the second busbar 252 is depicted. When current flows through the first busbar 250 and the second busbar 252 in opposite directions, the current flows through a bottom surface 258 of the first busbar 250 and a top surface 260 of the second busbar 252, respectively. This minimizes the current flow in the first busbar 250 and the second busbar 252, as the current flows in a smaller area or cross-sectional area of ​​the first busbar 250 and the second busbar 252.

[0020] As generally shown in Figure 208, a cross-sectional view of the first busbar 250, the second busbar 252, and a third busbar 270 is presented. The current flow through the first busbar 250 and the second busbar 252 is similar to that shown in Figure 206. However, parasitic current is present in the third busbar 270, resulting in a net zero current value. For example, the third busbar 270 exhibits a parasitic current flowing in opposite directions on the top and bottom surfaces of the third busbar 270. This phenomenon can increase the overall temperature of the busbars 250, 252, and 254.

[0021] As is generally the case with 210 in relation to Fig. Figure 4 shows a top view of the first busbar 250, the second busbar 252, the third busbar 270, and a fourth busbar 272. The fourth busbar 272 can be added in an attempt to increase the current flow. The current flow through the first busbar 250 and the second busbar 252 is similar to that shown in the Fig. This arrangement shown in 210 demonstrates that parasitic currents 280a, 280b, 280c and 280n are present on both the top and bottom of the third busbar 270 and the fourth busbar 272, leading to an additional temperature increase.

[0022] Fig. Figure 5 shows a perspective view of the busbar arrangement 114 and Fig. Figure 6 shows an exploded view of the busbar assembly 114 according to one embodiment. The busbar assembly 114 is generally arranged in an interlocking fashion from the busbar plates 121, 123, and / or 125. For example, the busbar 121 can be formed from an upper plate 121a and a lower plate 121b, the busbar 123 from a first middle plate 123a and a second middle plate 123b, and the busbar 125 from an upper plate 125a and a lower plate 125b. The upper plate 121a and the lower plate 121b of the busbar 121 can be connected to the terminal 119a on the secondary side 117 of the transformer 112. The upper plate 121a and the lower plate 121b generally allow a current flow that returns to the secondary side 117 of the transformer 112.The first middle plate 123a and the second middle plate 123b of busbar 123 can be connected to terminal 119b on the secondary side 117 of transformer 112. The first middle plate 123a and the second middle plate 123b of busbar 123 allow current flow from the secondary side 117 of transformer 112 to the low-voltage bus 106. The upper plate 125a and the lower plate 125b of busbar 125 can be connected to terminal 119n on the secondary side 117 of transformer 112. The upper plate 125a and the lower plate 125b of the busbar 125 generally allow current flow or return to the secondary side 117 of the transformer 112. The busbars 121, 123, and 125 are generally connected to a printed circuit board (PCB) 302. The various electronics, as described above in conjunction with... Fig. As mentioned in point 1, they can also be coupled to the PCB 302. In one example, the PCB 302 can generally be located in a horizontal plane.

[0023] Each of the busbars 121, 123 and 125 includes at least one encompassing extension section that extends horizontally across PCB 302. In the Fig. In the example shown for busbar 121, the upper plate 121a includes a first extension section 320a and the lower plate 121b includes a second extension section 320b. For busbar 123, the first middle plate 123a includes a first extension section 322a and the second middle plate 123b includes a second extension section 322b. For busbar 125, the upper plate 125a includes a first extension section 324a and the lower plate 125b includes a second extension section 324b. Each of the first extension sections 320a, 322a, 324a and the second extension sections 320b, 322b and 324b extend across the printed circuit board 302. In one example, each of the first extension sections 320a, 322a, 324a and the second extension sections 320b, 320b, 324b can be axially spaced from the PCB 302 (or parallel to a top face of the PCB 302).

[0024] For the busbar 121, the upper plate 121a includes a first connecting section 340a (see Fig. 7) with connecting sections 341 and the lower plate 121b a second connecting section 340b with connecting sections 343 each for connection to the printed circuit board 302 (see also Fig. 6 and Fig. 7) The first connecting section 340a and the second connecting section 340b are generally perpendicular or orthogonal to the first extension section 320a and the second extension section 320b. The connecting sections 341 of the upper plate 121a are spaced apart from each other. The connecting sections 343 of the lower plate 121b are spaced apart from each other. Additionally, the upper plate 121a includes a ramp section 360a and a connecting section 362a. The lower plate 121b includes a ramp section 360b and a connecting section 362b. A fastening mechanism (not shown) can be inserted into an opening formed in the connecting sections 362a and 362b. The connecting sections 362a - 362b can extend beyond the circuit board 302 so that fastening mechanisms (not shown) can couple the busbar 121 to the terminal 119a (of a transformer).

[0025] The first middle plate 123a and the second middle plate 123b of the busbar 123 each comprise a first connecting section 342a and a second connecting section 342b (see Fig. 6 - 8). It is acknowledged that the first middle plate 123a and the second middle plate 123b are separate from each other, but that the first middle plate 123a and the second middle plate 123b can be connected via the first connecting section 342a and the second connecting section 342b for the first middle plate 123a and the second middle plate 123b, respectively, using the same holes in the printed circuit board 302. The first connecting section 342a for the first middle plate 123a and the second middle plate 123b can be positioned on the rear side of the busbar 123 and extend along a first axis 345. The second connecting section 342b for the first middle plate 123a and the second middle plate 123b can be arranged between the first extension section 322a and the second extension section 322b and extend along a second axis 347 of the busbar 123.The first axis 345 can generally be perpendicular to the second axis 347. Each of the first interconnection sections 342a for the first middle plate 123a and the second middle plate 123b includes interconnection sections 351a–351x for coupling to the printed circuit board 302. The first interconnection section 342a and the second interconnection section 342b are generally perpendicular or orthogonal to the first extension section 322a and the second extension section 322b. The interconnection sections 351a–351x are spaced apart. Additionally, the first middle plate 123a includes a encompassing first ramp section 370a and a first interconnection section 372a. The second middle plate 123b includes a second ramp section 370b and a second interconnection section 372b.The first ramp section 370a can be positioned behind the second ramp section 370b, and the first connecting section 372a can be positioned below the second connecting section 372b. The fastening mechanism (not shown) can be inserted into an opening formed in the first connecting section 372a to connect the busbar 123 to the circuit board 302.

[0026] The busbar 125 comprises a first connection section 344a and a second connection section 344b. The first connection section 344a includes connection sections 355a–355x, and the second connection section 344b includes connection sections 357a–357x for coupling to the printed circuit board 302. The first connection section 344a and the second connection section 344b are generally perpendicular or orthogonal to the first extension section 324a and the second extension section 324b. Connection sections 355a–355x and connection sections 357a–357x are spaced apart. Additionally, the upper plate 125a includes a ramp section 380a and a connection section 382a. The lower plate 125b includes a ramp section 380b and a connection section 382b.The fastening mechanism (not shown) can be inserted into an opening formed in the connecting sections 382a, 382b to couple the base plate 114n to the circuit board 302.

[0027] Fig. Figure 7 typically shows a frontal section through the busbar assembly 114 according to one embodiment. The view of the busbar assembly 114 does not include the various ramp sections 360a, 360b, 370a, 370b, 380a, 380b and the connecting sections 362a, 362b, 372a, 372b, 382a, 382b for the corresponding busbars 121, 123 and 125, to illustrate the connecting sections 340a, 340b, 342a, 342b, 344a and 344b. The first connecting section 340a is arranged directly next to the second connecting section 340b of the busbar 121. A corresponding pair of connecting sections 341 and 343 for the busbar 121 can be inserted into a single through hole within the printed circuit board 302. The first connecting sections 344a are arranged directly next to the second connecting section 344b of the busbar 125.

[0028] Fig. Figure 8 shows a perspective view of the busbar assembly 114 according to one embodiment. View 400 is provided, which generally shows an effective current flow through a cross-section of the upper plate 121a and the lower plate 121b of busbar 121 and the first middle plate 123a of busbar 123. The first middle plate 123a of busbar 123 is generally located between the upper plate 121a and the lower plate 121b. It is acknowledged that view 400 can also correspond to the upper plate 125a and the lower plate 125b of busbar 125 and the second middle plate 123b of busbar 123. The second middle plate 123b of busbar 123 is generally positioned between the upper plate 125a and the lower plate 125b.As mentioned above, busbars 121 and 125 generally allow current to flow back to the secondary side 117 of transformer 112 in system 100. Busbar 123 allows current to flow from the secondary side 117 of transformer 112 to the low-voltage busbar 106 in system 100. As shown for busbar 121, current flows on a lower section of the upper plate 121a that is closer to the first middle plate 123a. Similarly, current flows in the opposite direction on an upper section of the first middle plate 123a that is closer to the upper plate 121a. Additionally, current flows in the same direction on a lower section of the first middle plate 123a that is closer to an upper section of the lower plate 121b.Furthermore, current flows in the opposite direction on the upper section of the lower plate 124b, which is located closer to a lower section of the first middle plate 123a. Thus, the effective current flowing through the busbar 123 (the first middle plate 123a or the second middle plate 123b) is generally doubled. This arrangement utilizes a larger cross-sectional area (or effective cross-sectional area) of the busbar 123 to allow current passage through it. This arrangement also reduces the temperature across the busbar 123 by approximately half, as the generation of parasitic currents due to the interlocking nature of the busbars 121, 123, and / or 125 described here can be avoided.

[0029] Fig. Figure 9 shows another perspective view of part of the busbar assembly 114 according to one embodiment. The busbar assembly 114, as shown in Fig. Figure 9 does not illustrate busbars 121 and 125. The busbar assembly 114 includes a first spacer 500 and a second spacer 502. As shown, the first spacer 500 is positioned directly on top of the first middle plate 123a and the second middle plate 123b to prevent these plates from coming into physical contact with the top plate 121a of busbar 121 and the top plate 125a of busbar 125. The second spacer 502 is positioned directly below the first middle plate 123a and the second middle plate 123b to prevent these plates from coming into physical contact with the bottom plate 121b of busbar 121 and the bottom plate 125b of busbar 125. As shown in Figure 400 of Fig. Figure 8 shows that since the first middle plate 123a and the second middle plate 123b allow current to flow in a different direction than the plates 121a, 121b, 125a, 125b of the busbars 121 and 125, the first and second middle plates 123a, 123b are physically isolated from the plates 121a, 121b, 125a, 125b of the busbars 121 and 125.

[0030] The first spacer 500 prevents the first extension section 322a and the second extension section 322b of the busbar 123 from touching the underside of the first extension section 320a of the busbar 121 and the first extension section 324a of the busbar 125. The second spacer 502 prevents the first extension section 322a and the second extension section 322b of the busbar 123 from touching the top side of the second extension section 320b of the busbar 121 and the top side of the second extension section 324b of the busbar 125.

[0031] The first spacer 500 comprises a first spacer ramp section 520a and a second spacer ramp section 520b. The first spacer ramp section 520a and the second spacer ramp section 520b are arranged below ramp section 360a of busbar 121 and ramp section 380a of busbar 125 to prevent contact between busbars 121 and 123. The second spacer 502 comprises a first spacer ramp section 522a and a second spacer ramp section 522b. The first spacer ramp section 522a and the second spacer ramp section 522b are arranged below ramp sections 370a and 370b of busbar 123 to prevent contact between busbars 123 and 125.The second spacer 502 generally comprises a plurality of guide tongues 550a–550n arranged on one wall 552 thereof to receive the lower plate 125b of the busbar 125 and guide it to the second spacer 502. The plurality of guide tongues 550a–550n ensures that the busbars 121 and 125 are not separated from the busbar 123. The plurality of guide tongues 550a–550n (not shown) can be positioned on the other side of the wall 552 (i.e., facing sideways) to receive the lower plate 121b of the busbar 121 and guide it to the second spacer 502. Although not shown, the first spacer 500 can also include on the wall 552 a comprehensive variety of guide tongues 550a - 550n for receiving and guiding the upper plate 121a of the busbar 121 and the upper plate 125a of the busbar 125 to the first spacer 500.

[0032] Fig. Figure 10 shows a cross-sectional view of the busbar assembly 114 (for example, only the busbars 123 and 125) including the first spacer 500 and the second spacer 502 according to one embodiment. The first spacer 500 further comprises an upper surface 500a to laterally insulate the busbar 121 and the busbar 125. The first spacer 500 includes the guide tongues 550a - 550b for holding the busbars 121 and 125, thereby preventing the busbars 121 and 125 from moving upwards. The first spacer 500 and the second spacer 502 comprise a corresponding wall (not shown) which includes the plurality of guide tongues 550a - 550n for receiving the busbar 123 relative to the busbar 125. Fig. Figure 11 shows an exploded underside view of the busbar assembly 114 in accordance with one embodiment.

[0033] Fig.Figure 12 shows another cross-sectional view of the busbar assembly 114 together with the first spacer 500 and the second spacer 502 according to one embodiment. The first spacer 500 comprises a first separating section 600 that isolates the upper plate 121a of busbar 121 from the upper plate 125a of busbar 125. As shown, the first separating section 600 can be U-shaped. It is recognized that the first separating section 600 can assume any number of shapes to isolate the upper plate 121a of busbar 121 from the upper plate 125a of busbar 125. Similarly, the second spacer 502 can comprise a second separating section 602a that isolates the lower plate 121b of busbar 121 from the first middle plate 123a of busbar 123.The second spacer 502 can also include a third separating section 602b, which isolates the lower plate 125b from the second middle plate 123b of the busbar 123.

[0034] While the first spacer 500 and the second spacer 502 are generally configured to accommodate the various busbars 121, 123, and 125, parts of the busbars 121, 123, and 125 are attached to themselves. For example, the first connecting section 340a of the upper plate 121a and the second connecting section 344b of the lower plate 121b can be welded or riveted together to attach the upper plate 121a and the lower plate 121b of busbar 121 to each other. Additionally or alternatively, the connecting sections 362a and 362b of busbar 121 can be riveted or soldered together. Similarly, the first connecting section 342a of the first middle plate 123a and the second middle plate 123b of busbar 123 can be welded or riveted together.Additionally or alternatively, the connecting sections 372a and 372b of the busbar 123 can be riveted or soldered together. The second connecting section 342b of the first middle plate 123a and the second middle plate 123b can be welded or riveted together. The first connecting section 344a of the upper plate 125a and the second connecting section 344b of the lower plate 125b may be welded or riveted together to fasten the upper plate 125a to the lower plate 125b. Additionally or alternatively, the connecting sections 382a and 382b of the busbar 125 can be riveted or soldered together. The entire assembly 114 can be soldered to the circuit board 302.

Claims

[1] Busbar arrangement (114) for a vehicle (102), the arrangement comprising: a printed circuit board (PCB, 302); a first plate (121a) which is supported on the printed circuit board (302) and is configured to allow a first current to flow in a first direction; a second plate (123) supported on the printed circuit board (302) and comprising a first middle plate (123a) positioned below the first plate (121a) to allow a second current flow in a second direction; and a third plate (121b) supported on the printed circuit board (302) and positioned below the first middle plate (123a) of the second plate (123) to allow the first current flow in the first direction, wherein the positioning of the first plate (121a), the second plate (123) and the third plate (121b) relative to each other forms an interlocking arrangement for the busbar arrangement (114), wherein the second current flowing through the second plate (123) is increased by an effective cross-section of the second plate (123), and wherein the interlocking arrangement reduces a temperature above the second plate (123) when the flux of the second current in the second direction differs from the flux of the first current in the first direction relative to an arrangement in which the second current flows in the same direction as the first current, wherein the interlocking arrangement reduces a parasitic current in the second plate (123) if the flux of the second current in the second direction differs from the flux of the first current in the first direction, and wherein the first plate (121a) comprises a first ramp section (360a) extending below the first plate (121a), and wherein the third plate (121b) comprises a second ramp section (360b) which extends below the third plate (121b) and is axially aligned with the first ramp section (360a). [2] Busbar arrangement (114) according to claim 1, further comprising a fourth plate (125a) which is separated from the first plate (121a) and supported on the printed circuit board (302) to allow current flow in the first direction. [3] Busbar arrangement (114) according to claim 2, wherein the second plate (123) comprises a second middle plate (123b) which lies in the same plane as the first middle plate (123a) and is arranged below the fourth plate (125a). [4] Busbar arrangement (114) according to claim 3, further comprising a fifth plate (125b) supported on the printed circuit board (302) and positioned below the second middle plate (123b) to allow current flow in the first direction. [5] Busbar arrangement (114) according to claim 4, wherein the first plate (121a) and the fourth plate (125a) are positioned on the same plane relative to each other and wherein the third plate (121b) and the fifth plate (125b) are positioned on the same plane relative to each other.

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