Stacked Busbar Connecting Mechanism for Low-EMI EV Charging
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Solution Overview
Problem
The high-voltage connecting mechanisms in electric vehicle charging systems have complex structures, high costs, and significant electromagnetic interference issues, necessitating costly shielding layers, which increase weight and complexity.
Innovation Solution
A connecting mechanism featuring stacked busbars with a proper interval, integrated injection-molded shells, and a conductive anticorrosion layer, eliminating the need for shielding layers and reducing costs by simplifying assembly and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional copper wire charging harness is used, then electrical connection is achieved, but structure becomes complicated and cost increases
Solution Approach 1:
The patent extracts the essential function of electrical connection from the complex traditional charging harness structure, eliminating unnecessary components such as connectors, terminals, and shielding layers, retaining only the critical busbar and shell structure needed for reliable electrical connection
Solution Approach 2:
The patent merges multiple functions into the busbar structure itself: the busbar serves as both the electrical conductor and the structural framework, while the shell integrates insulation and protection functions, eliminating the need for separate components and simplifying the overall structure
2Object-affected harmful factors
If shielding layer is added to high-voltage charging harness, then electromagnetic interference is reduced, but cost and weight increase
Solution Approach 1:
The patent converts the harmful electromagnetic interference into a beneficial self-shielding effect by strategically stacking multiple busbars with alternating current directions, where the magnetic fields generated by adjacent busbars naturally cancel each other out, eliminating the need for additional shielding layers
Solution Approach 2:
The patent changes the spatial arrangement parameter of the busbars from traditional side-by-side layout to vertical stacking configuration, and optimizes the current direction parameters to achieve magnetic field cancellation, thereby reducing electromagnetic interference without adding weight
3Object-affected harmful factors
If busbars are stacked with proper interval, then electromagnetic interference is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent merges the busbar and its support structure into an integrated component where the busbar is directly formed on or integrated with the shell, eliminating separate assembly steps and reducing precision requirements for stacking multiple independent components
Solution Approach 2:
The patent performs preliminary positioning by integrating positioning features directly into the shell structure during molding, ensuring correct busbar placement before final assembly, thereby reducing the precision requirements for subsequent assembly operations
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
The solution effectively reduces electromagnetic interference, lowers costs and weight, and enhances the reliability and efficiency of electrical connections by using aluminum instead of copper and integrating memory alloy components for temperature-dependent functionality.
Implementation Method 1
When high current passes through the high-voltage charging harness, electromagnetic interference may be caused to other components. By stacking busbars with proper interval and configuring current directions, the magnetic fields cancel each other, reducing electromagnetic interference without requiring shielding layers
Implementation Method 2
The connecting mechanism integrates memory alloy components for temperature-dependent functionality, enabling automatic temperature monitoring and protection without additional temperature measuring structures
Data Source
AI summary
A connecting mechanism, an electrical energy transmission device and a motor vehicle, in which the connecting mechanism includes a male-end connecting mechanism and a female-end connecting mechanism, in which a male-end shell connected to the busbar and the flat terminal; the female-end connecting mechanism includes a plug-in terminal and a female-end shell connected to the plug-in terminal; the male-end connecting mechanism is electrically connected to the plug-in terminal in the female-end connecting mechanism through the flat terminal, and the male-end shell is connected to the female-end shell to form the connecting mechanism. The busbars are stacked at a proper interval to effectively reduce the electromagnetic interference to other parts after the busbars are energized, thereby achieving the goal of canceling a shielding layer structure of high-voltage charging harnesses and reducing the cost and weight.