Sealed Busbar Pass-Through for Electrical Machine Inverter Assemblies

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electrical machine systems face issues with hermetic sealing between the electrical machine and inverter compartments due to manufacturing tolerances and thermal expansion, necessitating busbar passages through a separating wall, which can compromise compartment integrity.

Innovation Solution

A busbar design with rigid and flexible portions, combined with a sealing device, including a sleeve and sealing ring, ensures hermetic sealing while accommodating positional changes, using screws for compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If busbars are passed through the wall separating the two compartments, then electrical connection between electrical machine and inverter is achieved, but hermetic sealing between compartments is compromised

Engineering Contradiction:

Improveelectrical connectionVSAvoidcompromised hermetic sealing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The busbar is nested within a sealing structure where the sealing device is positioned around the busbar as it passes through the wall. The sealing device includes a sealing element that contacts both the busbar and the wall, creating a hermetic seal that prevents fluid leakage while allowing the busbar to maintain electrical connection through the compartment separator.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The sealing device acts as an intermediary element between the busbar and the wall. It mediates between the need for electrical connection (busbar passing through) and the need for hermetic sealing (preventing fluid transfer), by providing a sealing interface that accommodates the busbar while blocking fluid paths.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the relative position of electrical machine and inverter changes due to manufacturing tolerance and thermal expansion, then assembly flexibility is improved, but hermetic sealing integrity deteriorates

Engineering Contradiction:

Improveposition adjustment capabilityVSAvoidsealing integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The sealing device incorporates dynamic elements such as elastic sealing rings or compressible sealing materials that can adapt to position changes. These elements maintain sealing contact despite movements of the busbar caused by thermal expansion or manufacturing tolerances, ensuring continuous hermetic sealing without compromising integrity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The sealing device utilizes materials or mechanisms that change their physical parameters (such as elasticity, compression, or deformation) in response to position variations. This allows the sealing interface to maintain effective contact and hermetic sealing even when the relative position between electrical machine and inverter changes.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a rigid busbar structure is used to maintain electrical connection, then electrical conductivity is improved, but adaptability to position changes deteriorates

Engineering Contradiction:

Improveelectrical conductivityVSAvoidposition compensation capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The busbar is segmented into multiple sections with different properties. Some segments are rigid to maintain electrical conductivity, while other segments (such as flexible connectors or expansion joints) allow for position adjustments. This segmentation enables the busbar to maintain both electrical connection and adaptability to thermal expansion or manufacturing variations.

Inventive Principle:

Principle #1Segmentation

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

Maintains hermetic sealing between compartments, preventing fluid transfer and ensuring proper operation of components despite positional variations.

Implementation Method 1

the two compartments need to be hermetically sealed from each other because of different requirements needed for each of them

Methodology Applied

Scientific EffectHermetic sealing:

Implementation Method 2

the relative position of the electrical machine and the inverter may be different from what was designed due to manufacturing tolerance and/or may change during functioning due to thermo-expansion

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS20250211052A1Electrical machine system and mobility device comprising such an electrical machine system

Publication Date: 2025.06.26 VALEO EAUTOMOTIVE GERMANY GMBH

AI summary

An electrical machine system includes an electrical machine, an inverter, and a wall with a hole. The electrical machine and the inverter extend respectively on two sides of the wall. Several busbars connect the electrical machine and the inverter, at least one of the busbars includes a first portion extending on the side of the electrical machine, a second portion extending on the side of the inverter, and a rigid central portion connecting the first and second portions, the central portion going through the hole of the wall. At least one of the first portion and the second portion includes a braided portion and a sealing device between the wall and the central portion of the busbar.