Multi-layer Transfer Conductor for Electric Vehicle High Current

Solution Overview

Problem

High voltage systems in electric and hybrid vehicles face inefficiencies due to the skin effect, which increases resistance and causes AC current to crowd towards the surface of conductors, leading to uneven current distribution and voltage spikes.

Innovation Solution

The use of transfer conductors with multiple overlapping conducting layers arranged in parallel and insulation layers between them, which distributes current uniformly across the conductor, reducing skin effect and voltage gradients, and providing a flexible and lightweight alternative to solid copper conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional solid copper conductors are used, then current transmission capability is maintained, but skin effect increases resistance and causes uneven current distribution

Engineering Contradiction:

ImproveAC current lossesVSAvoidconductor structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The conductor is divided into multiple thin conducting layers (e.g., copper foils) separated by insulation layers, replacing a single solid conductor. This segmentation reduces the skin effect by distributing current across multiple layers, thereby reducing AC current losses and improving energy efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductor uses a composite structure combining multiple conducting layers with insulation layers (e.g., polyethylene terephthalate or polyvinylidene fluoride) in between. This composite design maintains current transmission capability while reducing skin effect and improving flexibility.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple overlapping conducting layers with insulation layers are used, then skin effect is reduced and current distribution is uniform, but conductor structure becomes more complex

Engineering Contradiction:

Improvecurrent distribution uniformityVSAvoidconductor structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The conductor is divided into multiple thin conducting layers (e.g., copper foils) separated by insulation layers, replacing a single solid conductor. This segmentation reduces the skin effect by distributing current across multiple layers, thereby reducing AC current losses and improving energy efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple conducting layers and insulation layers are merged into a single integrated conductor assembly that functions as one unified current transmission component, simplifying installation and maintenance despite the multi-layer internal structure.

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If solid copper conductors are replaced with layered conductors, then flexibility and weight are improved, but manufacturing complexity increases

Engineering Contradiction:

Improveconductor weightVSAvoidconductor manufacturing

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The conductor uses thin flexible conducting layers (e.g., copper foils) instead of rigid solid copper conductors. This provides significant weight reduction and improved flexibility for routing in vehicle applications, while the layered structure allows for manageable manufacturing processes.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The conductor uses a composite structure combining multiple conducting layers with insulation layers (e.g., polyethylene terephthalate or polyvinylidene fluoride) in between. This composite design maintains current transmission capability while reducing skin effect and improving flexibility.

Inventive Principle:

Principle #40Composite materials

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 configuration results in lower AC current losses, reduced voltage spikes, and improved flexibility and weight reduction compared to traditional solid conductors, while maintaining efficient high current transmission.

Implementation Method 1

The skin effect is a phenomenon wherein the AC has the tendency to crowd toward the surface of the conductor. The depth of penetration of the current can be referred to as the skin depth. The occurrence of skin effect undesirably increases the resistance to AC current flowing through the conductor.

Methodology Applied

Scientific EffectSkin effect: Skin Effect

Data Source

PatentUS9731603B2Electric and hybrid vehicle high current conductor

Publication Date: 2017.08.15 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

An apparatus for transferring electrical current between a first component and a second component includes at least one transfer conductor directing electrical current between the first and second components including a plurality of overlapping conducting layers each arranged in parallel with the directed electrical current and a plurality of insulation layers each disposed between alternating ones of the conducting layers.