Spray-Coated HV Busbar Contacts for Low-Resource Corrosion Protection
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Solution Overview
Problem
Existing methods for manufacturing high-voltage busbars in vehicles are resource-intensive and environmentally unfriendly, particularly due to the high consumption of chemicals, energy, and water in galvanic coating processes.
Innovation Solution
A method involving partial spraying of molten corrosion-protective metals, such as tin, zinc, or silver, onto specific contact regions of a copper or aluminum busbar body, reducing material usage and eliminating the need for harmful chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanic coating process is used to coat busbar contact surfaces, then corrosion protection and contact reliability are improved, but resource consumption (chemicals, energy, water) and environmental impact increase significantly
Solution Approach 1:
The patent changes the coating method from galvanic (electrochemical) to thermal spraying (thermo-mechanical), fundamentally altering the process parameters. This involves heating the coating material to melting temperature and applying it through a spray nozzle, eliminating the need for electrolytes, electrical current, and extensive water rinsing, thereby reducing resource consumption while maintaining coating quality
Solution Approach 2:
The patent replaces the electrochemical galvanic system with a thermal-mechanical spraying system. Instead of using electrical current to deposit metal ions, the invention uses a spray nozzle to mechanically project molten or semi-molten coating material onto the busbar surface, achieving corrosion protection without the environmental burden of chemical baths
2Reliability
If full busbar coating is applied to protect all surfaces, then corrosion protection is maximized, but material consumption and processing time increase
Solution Approach 1:
The patent applies corrosion protection only to the contact surfaces of the busbar that require it, rather than coating the entire busbar. The thermal spraying method allows precise targeting of specific areas, reducing coating material consumption while maintaining adequate protection where needed. Non-contact surfaces remain uncoated, eliminating unnecessary material use
3Reliability
If hot-dip tinning process is used to coat busbar, then corrosion protection is achieved, but defined contact surface properties are difficult to obtain
Solution Approach 1:
The patent changes from immersion-based hot-dip tinning to directed thermal spraying. By controlling spray parameters such as nozzle distance, spray angle, material feed rate, and substrate temperature, the process achieves precise control over coating thickness and properties. This allows defined contact surface characteristics to be obtained, overcoming the limitations of hot-dip methods
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
This approach significantly reduces resource consumption, minimizes environmental impact, and ensures durable, reliable electrical contacts by forming a protective coating that adapts to contact pressures and maintains low resistance.
Implementation Method 1
spraying at least one of the contact regions with a material stream of a molten corrosion-protective metal
Implementation Method 2
building up, in particular forming, the contact surface with or by coating the contact region with the corrosion-protective metal
Implementation Method 3
The spraying can also be referred to as partial or area-by-area spraying
Data Source
Figure 1a~2c
Figure 3a~4
AI summary
The disclosure relates to a method for manufacturing a high-voltage busbar (1) for current transmission in a vehicle, in particular for current transmission in an electrically driven vehicle, comprising providing a busbar body (2) made of a copper metal or of an aluminum metal as an oxide-layer-forming metal, the busbar body (2) having a first contact region (3) and at least one further contact region (3', 3", 3‴) spatially separated from the first contact region (3', 3", 3‴), which are each designed for a corresponding contact surface (5, 5', 5", 5‴) for establishing electrical contact with the busbar body (2); and with spraying at least one of the contact regions (3, 3', 3", 3‴) with a material stream (11) of a molten corrosion-protective metal (12) and thus building up the contact surface (5, 5', 5", 5‴) in order to provide a resource-saving, in particular environmentally friendly, flexible and easy-to-handle method for producing a permanently reliable high-voltage busbar (1), as well as to a high-voltage busbar (1) produced by such a method.