Dissimilar Material Busbar for Weight Reduction
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Solution Overview
Problem
Conventional busbars in electrified vehicles, typically made of copper, contribute significantly to the vehicle's weight due to their material density, which is a concern for efficiency and performance.
Innovation Solution
A busbar assembly comprising a copper strip and an aluminum strip, where the copper strip is metallurgically bonded to the aluminum strip to facilitate electrical current flow while reducing overall weight by leveraging the lighter material of aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper is used for busbars, then electrical conductivity and reliability are improved, but vehicle weight increases significantly
Solution Approach 1:
The busbar assembly uses a composite structure with a copper strip metallurgically bonded to an aluminum strip. The copper portion provides excellent electrical conductivity and connection reliability, while the aluminum portion reduces overall weight. This composite material approach allows the busbar to achieve both high electrical performance and weight reduction simultaneously.
2Weight of moving object
If aluminum is used for busbars, then weight is reduced, but oxidation resistance and electrical conductivity deteriorate
Solution Approach 1:
By combining copper and aluminum in a metallurgically bonded structure, the invention leverages copper's superior oxidation resistance and electrical conductivity at the connection points, while using aluminum for the main body to achieve weight reduction. The copper strip ensures reliable electrical connection without oxidation issues.
Solution Approach 2:
The busbar assembly applies different material properties to different regions: copper is used at the connection portions where oxidation resistance and electrical conductivity are critical, while aluminum is used in the main body where weight reduction is the primary concern. This local differentiation of material quality optimizes overall performance.
3Weight of moving object
If dissimilar materials are bonded together, then weight reduction and electrical conductivity are improved, but manufacturing complexity increases
Solution Approach 1:
The invention employs metallurgical bonding to create a permanent, reliable connection between copper and aluminum strips. This bonding method, while requiring specialized processes, produces a strong, durable joint that maintains electrical conductivity and mechanical strength throughout the busbar's service life, justifying the manufacturing complexity through superior product performance.
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 busbar assembly effectively communicates electrical current while offering a weight reduction compared to a busbar made entirely of copper, maintaining ampacity through a consistent cross-sectional area and minimizing oxidation issues with the aluminum strip.
Implementation Method 1
a copper strip and an aluminum strip, where the copper strip is metallurgically bonded to the aluminum strip to facilitate electrical current flow
Implementation Method 2
The first and second strips are both configured to communicate electric current
Implementation Method 3
the first material forms a non-conductive oxide layer under given atmospheric conditions at a first rate, and the second material forms a non-conductive oxide layer under the given atmospheric conditions at a second rate that is faster than the first rate
Data Source
AI summary
An exemplary busbar assembly includes a first strip including a first material, and a second strip including a second material different than the first material. The first strip extends continuously from a first connector portion to a second connector portion. The first connector portion electrically connects the first strip to a first structure. The second connector portion electrically connects the first strip to a second structure. The first and second strips are both configured to communicate electric current. An exemplary current communication method includes communicating electrical current using both a first strip and a second strip of a busbar. The first strip is made of a first material and bonded to the second strip made of a second material. The first strip extends continuously from a first to a second connector portion. The first connector portion electrically connects to a first structure, and the second connector portion electrically connects to a second structure.