Stacked Busbar Supports for Dense EV High-Current Insulation
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Solution Overview
Problem
Existing busbar arrangements in electrically driven motor vehicles face challenges in achieving high integration density with complex profiles while maintaining necessary clearances and creepage distances, and ensuring mechanical stability, especially due to increasing charging potentials and traction battery demands.
Innovation Solution
A busbar arrangement featuring stacked, planar supports made of electrically insulating material with trough-shaped receptacles for metal busbars, which are insulated and thermally conductive, allowing for compact, adhesive-free, and interference-fitted configurations with enhanced creepage distances and mechanical stability through the use of thermally conductive materials and insulating foils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are embedded in plastic to provide insulation, then electrical insulation is achieved, but the structure becomes complex due to differing coefficients of thermal expansion
Solution Approach 1:
The patent introduces an insulating foil as an intermediary layer between the busbar and the support structure. This foil provides the necessary electrical insulation while being flexible enough to accommodate thermal expansion differences, thereby avoiding the complexity of embedding busbars directly in plastic while maintaining reliable insulation.
2Reliability
If laminated busbars are used to achieve multipolar connection, then electrical connection is achieved, but complex busbar profiles cannot be realized and mechanical stability is insufficient
Solution Approach 1:
The patent employs a nested structure where trough-shaped recesses in the support hold the busbars, and insulating foils are nested between the busbar and the support. This nesting approach provides both electrical insulation and mechanical stability, while allowing complex busbar profiles to be accommodated within the trough structures.
3Volume of moving object
If integration density is increased to maximize battery space, then space utilization is improved, but clearance and creepage distances between busbars at different potentials become difficult to maintain
Solution Approach 1:
The patent transitions from planar insulation to three-dimensional insulation by implementing trough-shaped recesses in the support structure. These troughs vertically enclose the busbars, providing insulation in multiple dimensions. This allows compact arrangement of busbars while maintaining adequate clearance and creepage distances through the vertical walls of the troughs.
4Ease of manufacture
If adhesive-free accommodation is used to simplify assembly, then assembly complexity is reduced, but mechanical stability may be compromised
Solution Approach 1:
The patent employs curved, trough-shaped recesses in the support structure that provide form-fit accommodation for the busbars. The curved geometry of the troughs creates natural mechanical interlocking with the busbars, achieving stable mechanical fixation without adhesives while maintaining ease of assembly.
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 solution enables high integration density with complex busbar profiles, maintains compliance with clearance and creepage distance requirements, and provides long-term mechanical stability, while optimizing heat dissipation and reducing material usage through efficient thermal conductivity.
Implementation Method 1
a plurality of essentially planar supports (2a, 2b) formed of an electrically insulating material which are stacked in a stacking direction S
Implementation Method 2
allowing for compact, adhesive-free, and interference-fitted configurations with enhanced creepage distances and mechanical stability through the use of thermally conductive materials and insulating foils
Data Source
AI summary
The present disclosure relates to a busbar arrangement for electrical multipolar high-current connection in an electrically driven motor vehicle. The busbar arrangement includes a plurality of essentially planar supports formed of an electrically insulating material which are stacked in a stacking direction, each of which forms one or more trough-shaped receptacles which are open on one side; a plurality of busbars formed of a metal or of a metal alloy, each of which is accommodated in one of the trough-shaped receptacles; wherein at least one support of a plurality of essentially planar supports comprises a contact surface for a respective busbar, and thus a base forming a trough base of the trough-shaped receptacle and, for each trough-shaped receptacle, a first flange which circumferentially encloses the respective busbar and forms a side wall of the trough-shaped receptacle.