Color-Anodized Aluminum Busbars With Localized Contact Coating
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Solution Overview
Problem
Existing aluminum busbars in power converters face challenges in maintaining low transition resistance and corrosion protection, especially at high current densities, while conventional coatings like galvanic nickel-plating are costly and multilayered, and untreated aluminum surfaces are insufficient.
Innovation Solution
Combining anodization to create a colored surface on aluminum busbars followed by a cold gas coating to treat contact points, allowing for localized treatment and improved conductivity without full surface coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aluminum busbars are used instead of copper rails, then cost and weight are improved, but surface coating requirements increase to suppress aluminum oxide build-up
Solution Approach 1:
The patent applies different surface treatments to different regions of the aluminum busbar: anodization with coloring is applied to non-contact surfaces for corrosion protection and identification, while cold spray coating is applied only to contact points for low transition resistance. This local differentiation eliminates the need for complete surface coating while maintaining performance.
Solution Approach 2:
The surface treatment process is segmented into two distinct steps: first anodization for corrosion protection and coloring, then selective cold spray coating only at contact points. This segmentation allows each treatment to be optimized for its specific function without unnecessary overhead.
2Reliability
If cold spray coating is applied to create contact surfaces, then transition resistance is improved, but complete surface treatment increases manufacturing complexity
Solution Approach 1:
The cold spray coating is applied locally only at contact points rather than the entire surface. The patent specifies that cold gas coating is used 'at least on a first part of the surface' to create contact surfaces, eliminating the need for complete surface treatment while ensuring low transition resistance where needed.
3Ease of operation
If colored anodization is applied to busbars, then assembly and maintenance are simplified through functional identification, but additional manufacturing steps are required
Solution Approach 1:
The patent applies colored anodization to aluminum busbars to provide functional identification and hazard potential coding. Different colors indicate different functions or voltage levels, enabling quick visual identification during assembly and maintenance operations.
Solution Approach 2:
The anodization and coloring process is performed during manufacturing before final assembly, preparing the busbars with permanent visual identifiers that simplify subsequent assembly and maintenance operations. This preliminary action eliminates the need for separate labeling or marking steps.
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
The method enables colored busbars that facilitate easy assembly and maintenance by distinguishing functions and hazard potentials, reducing assembly time and enhancing corrosion resistance without the drawbacks of traditional coatings.
Implementation Method 1
the surface or at least parts of the surface of the aluminum busbar are provided with one or more specifiable colors by means of an anodizing treatment
Implementation Method 2
a cold gas coating is used at least on a first part of the surface in order to create a contact surface
Data Source
AI summary
In a method for producing a power converter, a surface or at least part of the surface of at least two aluminum busbars is subjected to an anodizing treatment to color the surface with at least one specifiable color, and a cold gas coating is applied on a first part of the surface to produce a contact surface.