Spray-Coated EV High-Voltage Busbar Contact Surfaces

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Solution Overview

Problem

Existing methods for manufacturing high-voltage busbars in vehicles are resource-intensive, environmentally unfriendly, and lack flexibility, particularly due to the high consumption of chemicals, energy, and water in galvanic processes.

Innovation Solution

A method involving partial spraying of a molten corrosion-protective metal onto specific contact regions of a copper or aluminum busbar body, reducing material usage and eliminating the need for harmful chemicals, while allowing for flexible application on varying busbar geometries.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If galvanic 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

Engineering Contradiction:

Improvecontact reliabilityVSAvoidresource consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent replaces the electrochemical galvanic process with a thermal spray coating process. Molten or semi-molten coating material is sprayed onto the busbar contact surface using a spray gun, eliminating the need for galvanic baths, chemicals, and extensive water consumption while achieving comparable or superior coating adhesion and protection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the coating application parameters from electrochemical (galvanic) to thermal (spray coating). The coating material is applied in a molten or semi-molten state and then cooled to form a adherent layer, fundamentally changing the physical state and application method to reduce resource consumption

Inventive Principle:

Principle #35Parameter changes

2Reliability

If full busbar coating is applied to protect all surfaces, then corrosion protection is maximized, but material consumption and processing time increase

Engineering Contradiction:

Improvecorrosion protectionVSAvoidcoating material consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies coating only to the contact surfaces of the busbar that require corrosion protection, rather than coating the entire busbar. This selective local coating reduces material consumption and processing time while maintaining protection where it is most needed for electrical contact reliability

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the busbar surface into contact regions requiring coating and non-contact regions that do not require coating. By identifying and treating only the specific contact surfaces, the process optimizes material usage and reduces waste

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If traditional electroplating in conveyor belt or immersion bath is used, then uniform coating is achieved, but device complexity and environmental impact increase

Engineering Contradiction:

Improvecoating uniformityVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex electroplating infrastructure (conveyor belts, immersion baths, power supplies, chemical handling systems) with a simpler thermal spray coating system using a handheld or automated spray gun, reducing device complexity while maintaining coating quality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The spray coating process allows for flexible, adaptable application that can accommodate various busbar geometries and sizes without requiring complex fixture systems or reconfiguration, enabling the process to serve diverse applications with a single versatile setup

Inventive Principle:

Principle #25Self-service

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, enhances environmental sustainability, and allows for efficient and flexible production of high-voltage busbars with improved durability and contact reliability.

Implementation Method 1

spraying at least one of the contact regions with a material stream of a molten corrosion-protective and thus contact-maintaining metal and thus building up, in particular forming, the contact surface

Methodology Applied

Scientific EffectSpray deposition: Deposition (physical)

Implementation Method 2

The coating of the busbar body created in this way by the corrosion-protective metal can have a thickness of at least 30 μm and/or at most 50 μm

Methodology Applied

Scientific EffectCooling and solidification: Freezing

Data Source

PatentUS20250201452A1Spray-Coated High-Voltage Busbar for a Vehicle, in Particular an Electric Vehicle

Publication Date: 2025.06.19 INTERCABLE AUTOMOTIVE SOLUTIONS GMBH

AI summary

A method for producing a high-voltage busbar for transmitting current in a vehicle is illustrated. The method includes providing a busbar body made of at least one of a copper metal or an aluminum metal as an oxide-layer-forming metal. The busbar body has a first contact region and at least one further contact region, each meant for a corresponding contact surface for establishing an electrical contact with the busbar body. The at least one further contact region is spatially separate from the first contact region. The method further includes spraying at least one of the contact regions with a material stream of a molten corrosion-protective metal and thereby building up the contact surface.