Composite Pipe Busbar Joining for Lower Weight and Cost
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rod-shaped busbars made entirely of copper are disadvantageous in terms of weight and cost due to their uniform material composition, which limits their application in high-power electrical components like electric vehicles.
Innovation Solution
A method for manufacturing a pipe-type busbar using a combination of copper, aluminum, and silver materials, where copper and aluminum tubular members are bonded using rotary friction welding, with silver plating to expose copper at contact points, reducing weight and cost while maintaining electrical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rod-shaped busbar is made entirely of copper material, then electrical conductivity is improved, but weight and cost increase
Solution Approach 1:
The busbar is constructed as a composite structure with a copper core providing electrical conductivity and an aluminum cladding layer reducing weight and cost. This composite material approach allows the busbar to maintain good electrical properties while significantly reducing weight compared to solid copper busbars.
Solution Approach 2:
Different regions of the busbar have different material compositions - the core uses copper for electrical conductivity while the outer surface uses aluminum for weight reduction. This local differentiation of material properties resolves the contradiction between conductivity and weight.
2Reliability
If a rod-shaped busbar is made entirely of copper material, then electrical conductivity is improved, but cost increases
Solution Approach 1:
The composite structure with copper core and aluminum cladding reduces material costs by using less expensive aluminum for the majority of the volume while maintaining electrical performance through the copper core.
Solution Approach 2:
Copper is applied locally only where electrical conductivity is critical (the core), while aluminum is used for the outer layers where cost reduction is prioritized, achieving cost-effective design without sacrificing essential electrical properties.
3Reliability
If plating is performed on all exposed outer surfaces of a copper busbar, then corrosion resistance is improved, but cost and weight increase
Solution Approach 1:
The aluminum cladding is applied selectively to outer surfaces where corrosion resistance is needed, replacing the need for extensive plating on copper surfaces. The aluminum layer provides protective function locally where required.
Solution Approach 2:
The aluminum cladding acts as a protective barrier against corrosion for the copper core, eliminating the need for additional plating layers and reducing overall material cost while maintaining corrosion resistance.
4Weight of moving object
If a pipe shape is used instead of rod shape, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The busbar is segmented into a copper core and aluminum cladding layers, with the cladding applied in sections rather than as a continuous solid structure. This segmentation allows the pipe shape to be manufactured more easily while maintaining weight reduction benefits.
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 results in a busbar that reduces weight by approximately 30% and cost compared to conventional rod-shaped busbars, while ensuring electrical stability and protection from physical damage through heterogeneous material composition.
Implementation Method 1
The bonding of one surface of the first tubular member and one surface of the second tubular member may bond one surface of the first tubular member and one surface of the second tubular member by rotary friction welding (RFW)
Implementation Method 2
plating the first tubular member with a third material
Data Source
AI summary
A method for manufacturing a pipe type busbar includes: preparing a first tubular member made of a first material having a hollow formed therein; preparing a second tubular member having a hollow formed therein and made of a second material different from the first material; plating the first tubular member with a third material; and bonding one surface of the first tubular member and one surface of the second tubular member.