Shielded Busbar for High-Power EV Charging
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Solution Overview
Problem
Traditional car wiring systems are inadequate for high-power distribution in electric vehicles, leading to increased complexity, cost, and difficulty in isolating and repairing failures in large cable assemblies.
Innovation Solution
A high power shielded busbar system with a solid core conductor, insulation layer, and outer shield, made from conductive materials like aluminum or copper, which is forged into desired shapes for reliable connections and can be bent to fit vehicle contours, reducing the need for traditional routing components and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional cable designs are used for power distribution, then the system can be easily manufactured and installed, but the cables cannot support high-power distribution exceeding several hundred kilowatts
Solution Approach 1:
The patent divides the power distribution system into modular busbar segments that can be independently manufactured and then assembled. Each busbar segment handles specific power levels, allowing the system to scale to high power levels (exceeding several hundred kilowatts) without requiring single complex cables. This segmentation enables manageable complexity while achieving high power distribution capability.
2Ease of repair
If traditional cable assemblies are used, then the system can be easily repaired, but failures are difficult to isolate and repair in large cable assemblies
Solution Approach 1:
By segmenting the power distribution into modular busbar sections with discrete connection points, the patent enables easier failure isolation. When a failure occurs, it can be localized to a specific segment rather than searching through a large integrated cable assembly. This modular approach maintains ease of repair while supporting high power distribution.
Solution Approach 2:
The patent introduces intermediate connection components and shielding layers that act as mediators between power conductors. These intermediaries provide structured access points and organizational layers that simplify troubleshooting and repair procedures in high-power systems without adding significant complexity.
3Power
If traditional cables are used for high-power distribution, then the system can handle high power, but the design becomes increasingly complex and costly
Solution Approach 1:
The busbar system is divided into standardized segments that can be manufactured using consistent processes and then assembled. This segmentation allows for economies of scale in manufacturing individual components while achieving high-power distribution capability in the complete system, reducing both complexity and cost compared to custom high-power cable designs.
Solution Approach 2:
The patent employs standardized parameters for busbar dimensions, connection interfaces, and shielding configurations. By maintaining consistent parameters across segments while scaling power capacity through quantity rather than individual component complexity, the system achieves high-power handling capability with manageable manufacturing complexity and cost.
Data Source
AI summary
A unitary busbar provides power from one connection point in an electric vehicle to another connection point. The unitary busbar includes a central solid core conductor, an insulation layer over the solid core conductor, and an electromagnetic shield fitted around the insulator. The unitary busbar is capable of being bent into specific configurations that allow it to conform to the body of an electric vehicle.