Selective Anodizing and Plating for Aluminum Busbar Insulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for insulating high current busbars in data centers are costly and not recognized by Underwriters Laboratories (UL), and aluminum busbars require surface coatings due to oxidation, necessitating a cost-effective and UL-recognized insulation solution.

Innovation Solution

A method involving pre-conditioning, anodizing select surfaces of aluminum busbars, and applying PTFE or tin coatings to specific areas, using a sealing jig for precise application, which includes zinc and nickel plating to enhance insulation and conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the busbar is coated on the full surface with epoxy or metal coatings, then insulation and oxidation resistance are improved, but cost increases significantly

Engineering Contradiction:

Improveinsulation performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies different surface treatments to different portions of the busbar: anodizing for insulation on non-contact surfaces and metal plating for conductivity on contact surfaces. This selective treatment optimizes both insulation performance and cost efficiency by avoiding unnecessary coating on areas where it is not required.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The busbar surface is divided into distinct zones with different functional requirements. Contact surfaces receive metal plating for conductivity while non-contact surfaces receive anodizing for insulation. This segmentation allows each portion to be optimized for its specific function rather than applying a uniform coating across the entire surface.

Inventive Principle:

Principle #1Segmentation

2Reliability

If aluminum busbar surfaces are coated with metal plating, then conductivity is improved, but oxidation resistance deteriorates on uncoated areas

Engineering Contradiction:

ImproveconductivityVSAvoidoxidation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies metal plating specifically to contact surfaces where conductivity is required, while applying anodizing to non-contact surfaces where oxidation resistance is the primary concern. This local differentiation ensures that each surface receives the treatment most appropriate for its functional requirements.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The busbar is segmented into contact and non-contact portions, with different surface treatments applied to each. This segmentation allows the metal-plated contact surfaces to maintain conductivity while the anodized non-contact surfaces provide oxidation resistance.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If Chrome III coating is applied to aluminum busbars, then surface treatment is achieved, but UL recognition is lost

Engineering Contradiction:

Improvesurface treatmentVSAvoidUL compliance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the non-UL-recognized Chrome III coating with UL-recognized alternatives: anodizing and metal plating with UL-approved metals. These treatments achieve the necessary surface protection and functional requirements while maintaining UL compliance, effectively substituting an non-compliant solution with compliant ones.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of manufacture

If aluminum busbars are used instead of copper, then material cost is reduced, but surface oxidation occurs more quickly

Engineering Contradiction:

Improvematerial costVSAvoidoxidation rate

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent applies anodizing specifically to the non-contact surfaces of aluminum busbars where oxidation resistance is critical for insulation. This targeted approach protects the aluminum from oxidation on surfaces exposed to air while maintaining the cost advantages of using aluminum instead of copper.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach creates a cost-effective, UL-recognized insulated busbar that can be bolted to other aluminum or copper busbars without electro-galvanic issues, reducing material usage and preventing short circuits while maintaining conductivity.

Implementation Method 1

anodizing one portion of the surface of the busbar

Methodology Applied

Scientific EffectAnodizing: Anodising

Implementation Method 2

anodizing one portion of the surface of the busbar

Methodology Applied

Scientific EffectElectrochemical oxidation: Oxidation

Implementation Method 3

plating another portion of the surface of the busbar with at least one metal

Methodology Applied

Scientific EffectMetal plating: Electroplating

Data Source

PatentEP3078032B1System for insulating high current busbars

Publication Date: 2020.05.06 SCHNEIDER ELECTRIC IT CORP

Figure 1~2
Figure 3
Figure 4~5

AI summary

A method of treating a surface of an aluminum busbar includes pre-conditioning the surface of the busbar, anodizing one portion of the surface of the busbar, and plating another portion of the surface of the busbar with at least one metal. A fixture used to secure a busbar for a treatment process is also disclosed.