Copper-Graphene Composite Busbar for EV Power Distribution

The patent applies composite materials by combining copper layers with graphene layers to create a copper-graphene composite busbar. This composite structure leverages the high electrical conductivity of both materials, with graphene providing enhanced electron transport pathways between copper layers, thereby reducing electrical energy loss while maintaining manageable structural complexity through standardized lamination processes.

The patent transitions from traditional three-dimensional copper busbar structures to a layered two-dimensional composite structure. Multiple thin copper layers are separated and connected by graphene layers, creating a distributed three-dimensional conductive network. This dimensional reorganization increases the effective conductive pathways and reduces resistance, thereby reducing energy loss.

The patent applies preliminary action by pre-suspending graphene layers on a carrier substrate before the lamination process. This preliminary preparation ensures precise positioning and alignment of graphene layers during subsequent copper layer deposition, maximizing conductivity without requiring complex real-time alignment mechanisms during manufacturing, thus maintaining ease of manufacture while achieving high reliability.

The patent uses a carrier substrate as an intermediary during the manufacturing process. The carrier substrate temporarily holds the graphene layers in the correct position and configuration, facilitating easy integration with copper layers during lamination. This intermediary approach simplifies the manufacturing process by decoupling the complex tasks of graphene positioning and copper deposition, while ensuring optimal conductivity for EV system performance.

The patent applies local quality by concentrating conductive materials only where electrically necessary. The alternating copper and graphene layers are strategically positioned to create high-density conductive pathways along current flow directions, while minimizing material usage in non-critical areas. This localized optimization achieves superior conductivity with reduced overall material quantity compared to bulk copper busbars.

The patent uses composite materials to replace a significant portion of copper with graphene, which has superior electrical conductivity per unit mass. The copper-graphene composite structure provides enhanced conductivity with less total material, as graphene's two-dimensional structure offers efficient electron transport pathways that reduce the need for large quantities of copper, thereby reducing environmental resource consumption.

The patent compensates for reduced busbar size by transitioning to a multi-layered three-dimensional structure. Thin copper and graphene layers are stacked and interconnected to create extensive conductive pathways within a compact volume. This dimensional organization maintains high power distribution capability despite reduced overall material quantity, as the layered architecture provides multiple parallel conduction channels that efficiently distribute electrical power.

The patent segments the busbar into multiple thin copper and graphene layers rather than using a single solid copper block. This segmentation creates numerous distributed conductive pathways that collectively provide high power distribution capability. The segmented structure achieves superior conductivity and power distribution in a smaller overall package, maintaining reliability while reducing material usage and environmental impact.