New patent application published for: COPPER-ALUMINUM BUSBAR WITH INTERLOCK INTERFACE

COPPER-ALUMINUM BUSBAR WITH INTERLOCK INTERFACE

Claims

1. A busbar with an interlock interface, the busbar comprising: an aluminum (Al) body including an upper surface and a lower surface opposing the upper surface; and a first copper (Cu) coil embedded within the Al body, the first Cu coil including: a first outer surface flush with the upper surface of the Al body; a first inner surface opposing the first outer surface; a first set of side surfaces positioned between and connected to the first outer surface and the first inner surface; and a first edge formed by the connection of the first set of side surfaces and the first inner surface, wherein the first edge defines a first angle between 20 and 70 degrees.
2. The busbar of claim 1, wherein the first edge is tapered.
3. The busbar of claim 1, wherein at least a portion of a perimeter of the first Cu coil is coated with one of the following: tin (Sn), nickel (Ni), and silver (Ag).
4. The busbar of claim 1, wherein the first set of side surfaces defines a first width increasing from the first inner surface towards the first outer surface.
5. The busbar of claim 1, wherein the first set of side surfaces defines a first width decreasing from the first inner surface towards the first outer surface.
6. The busbar of claim 5, further comprising a second Cu coil embedded within the Al body, the second Cu coil including: a second outer surface flush with the lower surface of the Al body; a second inner surface opposing the second outer surface; a second set of side surfaces positioned between and connected to the second outer surface and the second inner surface, wherein the second set of side surfaces defines a second width decreasing from the second inner surface towards the second outer surface; and a second edge formed by the connection of the second set of side surfaces and the second inner surface, wherein the second edge defines a second angle between 20 and 70 degrees.
7. The busbar of claim 6, wherein the first edge of the first Cu coil and the second edge of the second Cu coil are tapered.
8. The busbar of claim 6, further comprising a middle Cu portion, wherein the middle Cu portion is positioned between the first Cu coil and the second Cu coil, connecting the first Cu coil to the second Cu coil.
9. A method of forming a busbar comprising: heating an aluminum (Al) body to form liquid Al; channeling the liquid Al to water cooled rollers; feeding a first copper (Cu) coil between the water cooled rollers, wherein the first Cu coil is in contact with an upper surface of the liquid Al, wherein the water cooled rollers apply pressure against the first Cu coil and the liquid Al, and wherein the pressure embeds the first Cu coil within the liquid Al; cooling the liquid Al with the water cooled rollers, solidifying the liquid Al and bonding the first Cu coil to the solid Al; and creating a tensioned coil with the solid Al and the first Cu coil, forming the busbar.
10. The method of claim 9, further comprising cutting the first Cu coil to a first desired shape prior to feeding the first Cu coil between the water cooled rollers, the first desired shape including: a first outer surface flush with the upper surface of the Al; a first inner surface opposing the first outer surface; and a first set of side surfaces, wherein the first set of side surfaces defines a first angle, and wherein the first angle is between 20 and 70 degrees.
11. The method of claim 10, wherein the first desired shape defines a first width increasing from the first inner surface towards the first outer surface.
12. The method of claim 10, wherein the first desired shape defines a first width decreasing from the first inner surface towards the first outer surface.
13. The method of claim 10, further comprising cutting a second Cu coil to a second desired shape, the second desired shape including: a second outer surface flush with a lower surface of the Al; a second inner surface opposing the second outer surface; and a second set of side surfaces, wherein the second set of side surfaces defines a second angle, and wherein the second angle is between 20 and 70 degrees; and feeding the cut second Cu coil between the water cooled rollers, wherein the cut second Cu coil is in contact with a lower surface of the liquid Al, wherein the water cooled rollers apply pressure against the cut second Cu coil and the liquid Al, wherein the pressure embeds the cut second Cu coil within the liquid Al, and wherein the water cooled rollers solidify the liquid Al, bonding the cut second Cu coil to the solid Al.
14. The method of claim 13, wherein the first desired shape defines a first width decreasing from the first inner surface towards the first outer surface and wherein the second desired shape defines a second width decreasing from the second inner surface towards the second outer surface.
15. The method of claim 9, wherein the first Cu coil is a plurality of pultruded copper.
16. The method of claim 15, wherein the plurality of pultruded copper is hollow.
17. A method of forming a busbar comprising: heating an aluminum (Al) body to form liquid Al; channeling the liquid Al to water cooled rollers; cutting a first copper (Cu) coil to a first desired shape, wherein the first desired shape includes a first outer surface, a first inner surface, and a first set of side surfaces, wherein the first set of side surfaces defines a first angle, and wherein the first angle is between 20 and 70 degrees; feeding the cut first Cu coil between the water cooled rollers, wherein the cut first Cu coil is in contact with an upper surface of the liquid Al, wherein the water cooled rollers apply a pressure against the cut first Cu coil and the liquid Al, and wherein the pressure embeds the cut first Cu coil within the liquid Al; cooling the liquid Al with the water cooled rollers, solidifying the liquid Al and bonding the cut first Cu coil to the solid Al; and creating a tensioned coil with the solid Al and the cut first Cu coil, forming the busbar.
18. The method of claim 17, wherein the first desired shape defines a first width increasing from the first inner surface towards the first outer surface.
19. The method of claim 17, wherein the first desired shape defines a first width decreasing from the first inner surface towards the first outer surface.
20. The method of claim 19, further comprising cutting a second Cu coil to a second desired shape, the second desired shape including: a second outer surface flush with a lower surface of the Al; a second inner surface opposing the second outer surface; and a second set of side surfaces, wherein the second set of side surfaces defines a second angle between 20 and 70 degrees, and wherein the second desired shape defines a second width decreasing from the second inner surface towards the second outer surface; and feeding the cut second Cu coil between the water cooled rollers, wherein the cut second Cu coil is in contact with the lower surface of the liquid Al, wherein the water cooled rollers apply a pressure against the cut second Cu coil and the liquid Al, wherein the pressure embeds the cut second Cu coil within the liquid Al, wherein the water cooled rollers solidify the liquid Al, bonding the cut second Cu coil to the solid Al.