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TeslaGranted patentCars & transportInterest 6/10

Tesla patents bendable shielded cable for EV power distribution

Patent drawing
Patent drawing from the official filing.

Tesla has patented a single, solid power cable designed to move electricity around an electric vehicle. The cable features a metal core, an insulating layer, and a compressed metal shield that helps prevent electromagnetic interference. It is designed to be bent into specific shapes to fit tightly inside the car's body.

Why it mattersThis design could help engineers pack more power components into tight spaces in future electric vehicles while keeping the electrical signals clean.

In the filing’s own words

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.

What exactly they claim (claim 1)

1. An electric vehicle power distribution system comprising: a unitary busbar comprising a solid core conductor, an insulation layer surrounding the solid core conductor, a shielding layer compressed against the insulation layer, and at least one formed connector made from the solid core conductor, wherein the shielding layer comprises a metal shield tube directly surrounding and radially compressed against the insulation layer such that the solid core conductor, the insulation layer, and the metal shield tube form a unitary three-layer solid core busbar, and wherein the shielding layer is a conductive material formed from a single formed component; a first connection point configured to electrically connect with the at least one formed connector on the busbar; and a second connection point electrically coupled to the busbar at an end opposite to the at least one formed connector, wherein the unitary busbar is bent to conform to the interior configuration of the electric vehicle; and a rigid ground conductor connected to the shielding layer, wherein the shielding layer is grounded to the electric vehicle via the rigid ground conductor.

Facts

Company
Tesla (Tesla, Inc.)
Official title
High power shielded busbar for electric vehicle charging and power distribution
Patent number
US12766983B2
Application number
17912018
Filed
Mar 15, 2021
Granted
Oct 20, 2026
Inventors
2
Claims
16

Classified under

B60L 53/14 Operations & transportH02G 5/061 Electricity & electronics
Read the full filing (official PDF) ↗ Open in the Patent Tracker

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Summaries are simplified from the filing’s own abstract and first claim. A patent filing is not a product announcement.
Patent data and drawings: U.S. Patent and Trademark Office (USPTO). Nebula is not affiliated with or endorsed by the USPTO.