Low Inductance Busbar Assembly with Overlapping Bridge Electrodes
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Solution Overview
Problem
Conventional busbar systems in electric and hybrid electric vehicles experience voltage spikes due to high inductance, which complicates the design and increases part count and assembly complexity, while also being costly.
Innovation Solution
A low inductance busbar assembly is designed with overlapping conductive bridge electrodes and a single fastener configuration, reducing inductance by extending current pathways and simplifying assembly with fewer parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional busbar systems are used with separate connector terminals on each electrode, then electrical isolation between electrodes is maintained, but part count and assembly complexity increase
Solution Approach 1:
The patent combines multiple separate connector terminals into a single integrated connector assembly that interfaces with both positive and negative busbar electrodes simultaneously. This merging reduces the number of separate fasteners and assembly steps while maintaining electrical isolation through the connector's internal design, directly resolving the contradiction between reliability and assembly complexity.
2Object-generated harmful factors
If current pathways are extended to reduce inductance, then voltage spikes are reduced, but the busbar system complexity increases
Solution Approach 1:
The patent extends current pathways by adding vertical overlap between busbar electrodes in the z-dimension, rather than simply lengthening horizontal pathways. This dimensional approach reduces inductance and voltage spikes while maintaining a compact footprint and avoiding excessive system complexity.
3Object-generated harmful factors
If overlapping busbar electrodes are used to reduce inductance, then voltage spikes are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The connector assembly is designed to establish equipotential connections across multiple busbar electrodes simultaneously, ensuring that voltage potentials are equalized at connection points. This design approach reduces sensitivity to alignment variations and maintains manufacturing feasibility while achieving the voltage spike reduction benefits of overlapping electrodes.
Data Source
AI summary
A busbar assembly for electrically coupling first and second busbars to first and second contacts, respectively, on a power module is provided. The assembly comprises a first terminal integrally formed with the first busbar, a second terminal integrally formed with the second busbar and overlapping the first terminal, a first bridge electrode having a first tab electrically coupled to the first terminal and overlapping the first and second terminals, and a second tab electrically coupled to the first contact, a second bridge electrode having a third tab electrically coupled to the second terminal, and overlapping the first and second terminals and the first tab, and a fourth tab electrically coupled to the second contact, and a fastener configured to couple the first tab to the first terminal, and the third tab to the second terminal.