Graphene-Layer Busbar Assembly for Lightweight EV Power Distribution
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Solution Overview
Problem
Conventional copper or aluminum busbars in electric vehicles face challenges in reducing weight and cost without compromising electrical performance, as aluminum has lower conductivity than copper and composite structures with graphene are complex and not suitable for commercial applications.
Innovation Solution
A busbar assembly incorporating a body made of conventional conductive materials with integrated graphene layers, which enhance electrical conductivity, allowing for reduced copper or aluminum usage while maintaining performance, and utilizing thin insulating separators to minimize inductance and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum is used instead of copper to reduce weight and cost, then weight and cost are reduced, but electrical conductivity deteriorates
Solution Approach 1:
The patent uses a composite structure combining aluminum (for weight reduction) with copper layers (for electrical conductivity). The bi-metallic construction allows the busbar to achieve both lightweight properties and high electrical performance by strategically placing different materials in specific layers and positions.
2Reliability
If copper is used to maintain high electrical conductivity, then electrical performance is improved, but weight and cost increase
Solution Approach 1:
The patent applies local quality by placing copper layers specifically where electrical conductivity is most critical (in contact with semiconductor modules and at current distribution points), while using aluminum in other areas. This localized material placement optimizes electrical performance only where needed, reducing overall weight.
3Ease of manufacture
If conventional single-material busbars are used, then manufacturing is simple, but electrical performance and weight optimization are limited
Solution Approach 1:
The busbar is segmented into multiple layers with different materials (copper and aluminum) arranged in specific configurations. This segmentation allows each layer to perform its optimized function while maintaining a structured, manufacturable assembly process through layer-by-layer construction.
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 achieves improved electrical conductivity and reduced weight and cost, with a compact, high-current capacity, low-inductance structure that is easier to integrate and potentially smaller than traditional copper busbars.
Implementation Method 1
Graphene is very thin and flexible, yet conductive. Any amount of graphene coverage or structure of graphene that will provide the desired enhancement of the electrical conductivity in the busbar can be used.
Implementation Method 2
By combining several layers of graphene in parallel (such as for instance in the battery cell production technology), one can meet the same electrical property than copper.
Implementation Method 3
The separator provides an insulating layer appropriate for the voltage and current carried by the busbar and more particularly by the graphene layers.
Data Source
Figure 1
Figure 2A~2B
AI summary
Busbar assembly for an electric vehicle having a busbar for electric power distribution and a connector, wherein the busbar comprises a body made of a first conductive material, the body defining a recess in which a plurality of graphene layers is arranged, and in which the graphene layers contact the body.