Busbar conductor, busbar duct and power device

Abstract

The application discloses a bus conductor, a bus slot and a power device, the bus conductor comprises a head part and a rod part which are integrally formed, the width of the head part is greater than the width of the rod part, at least one side of the head part away from the rod part is in smooth arc transition, and a first positioning part is further arranged on the rod part. The application relies on the location advantage of the head part close to the external environment, increases the heat dissipation area through widening design, dissipates heat concentration through arc transition, and accelerates heat conduction. The heat dissipation improvement enables the conductor to upgrade the current carrying capacity without increasing the overall cross section, the narrow design of the rod part effectively controls the volume and weight of the conductor and the bus slot, adapts to narrow power distribution environment, and fits the miniaturization and high performance trend.

Description

Technical Field

[0001] This application relates to the technical field of busbar trunking, and more particularly to a busbar conductor, busbar trunking, and power equipment. Background Technology

[0002] Busbar conductors, as the core conductive components of busbar trunking, are widely used in power distribution systems. Their conductivity, heat dissipation, and assembly precision directly determine the overall operational reliability, installation efficiency, and applicable scenarios of the busbar trunking. In existing technologies, to simplify manufacturing processes and reduce on-site installation difficulties, busbar conductors generally adopt an integrated structural design, and these integrated conductors all have a regular and uniform shape.

[0003] However, the aforementioned traditional busbar conductor structures have significant technical defects, making it difficult to meet the development requirements of power distribution systems for miniaturized, high-performance, and easy-to-assemble busbars. Firstly, because the conductor is a uniformly shaped integrated structure, heat conduction and heat dissipation are limited, resulting in poor heat dissipation. In practical applications, if the conductivity of the conductor needs to be improved, it can only be achieved by increasing the cross-section of the conductor. This method directly leads to a significant increase in the overall size of the busbar conductor, not only increasing the overall volume and weight of the busbar but also imposing stringent requirements on installation space, severely limiting its application in confined power distribution environments. Secondly, the conventional production length of busbar conductors is mostly over 3 meters. The long, integrated structure increases the difficulty of rigidity and shape control, making it easy to generate assembly deviations during assembly. This makes it difficult to ensure the connection accuracy of the conductors, thereby affecting the stability of the busbar's conductive connection and increasing the on-site assembly and commissioning procedures and operating costs. Summary of the Invention

[0004] The purpose of this invention is to provide a bus conductor, a bus trunking, and a power device that can solve the aforementioned problems existing in the prior art.

[0005] To achieve the above objectives, this application adopts the following technical solution: On one hand, a bus conductor is provided, comprising: an integrally formed head and a rod, wherein the width of the head is greater than the width of the rod, and at least the side of the head away from the rod has a smooth arc transition, and the rod is further provided with a first positioning part.

[0006] Furthermore, the side of the rod is flat.

[0007] Furthermore, the outer contour of the head is dome-shaped, and the connection point with the rod is an arc transition.

[0008] Furthermore, the outer contour of the head is hat-shaped, with an arc-shaped top side and two sides extending vertically. The bottom end of the side extends horizontally toward the rod and connects to the side of the rod.

[0009] Furthermore, the first positioning part is a positioning groove provided on the side of the rod, and the positioning groove extends along the length direction of the rod.

[0010] Furthermore, the positioning groove is V-shaped and recessed into the side of the rod.

[0011] Furthermore, the head is provided with the first positioning part, which is a positioning groove located at the top of the head and extends along the length direction of the head.

[0012] Furthermore, the bottom side of the rod is provided with a contact portion that can make contact with the plug claw of the plug box to conduct electricity.

[0013] Furthermore, the contact portion includes two inclined sides that slope downwards from the outside to the inside, and the bottom ends of the two inclined sides intersect. Alternatively, the contact portion includes two inclined edges that slope upwards from the outside to the inside, and a circular groove connecting the tops of the two inclined edges.

[0014] Furthermore, the width of the head is 6-12mm, the width of the rod is 3-6mm, the height of the head is 8-12mm, and the height of the rod is 10-16mm.

[0015] On the other hand, a busbar trunking is also provided, comprising: a metal shell, an insulator, and a busbar conductor as described above. The metal shell is provided with a conductor groove for mounting the busbar conductor. The insulator is disposed between the conductor groove and the busbar conductor. A second positioning part is provided on the inner side of the insulator to cooperate with the first positioning part for positioning. Connectors are respectively provided on both sides of the end of the metal shell, and are connected to the end cap through the connectors. The metal shell is provided with a slot for mounting the connectors. Abutment portions are respectively provided on the opposite sides of the two connectors. The abutment portions abut against a portion of the slot side to form a limiting position.

[0016] On the other hand, an electrical device is also provided, comprising: a plug box, a connector, and a plurality of busbars as described above, wherein each pair of busbars is connected to the connector, and the plug box is electrically connected to the busbar conductors via plug claws.

[0017] The beneficial effects of this application are as follows: On the one hand, relying on the location advantage of the head being close to the external environment, the heat dissipation area is increased through widening design, and the arc transition achieves uniform heat dissipation, while avoiding heat concentration and accelerating heat conduction. The improved heat dissipation allows the conductor to upgrade its current carrying capacity without increasing the overall cross-section, and the narrow design of the pole effectively controls the volume and weight of the conductor and busbar, adapting to small power distribution environments and conforming to the trend of miniaturization and high performance.

[0018] On the other hand, the non-uniform structure optimizes the rigidity distribution, reducing the deformation and position control difficulty of long conductors; the first positioning part and the insulator are precisely matched, which not only ensures docking accuracy and conductivity stability, but also makes the assembly smoother by reducing assembly friction, simplifying the debugging process, reducing operating costs and improving installation efficiency. Attached Figure Description

[0019] The present application will now be described in further detail with reference to the accompanying drawings and embodiments.

[0020] Figure 1 This is a front view (excluding the first positioning part) of the dome-shaped busbar conductor described in the embodiment of this application. Figure 2 This is a front view of the cap-shaped busbar conductor described in the embodiment of this application (excluding the first positioning part); Figure 3 This is a front view (including a circular groove) of the dome-shaped busbar conductor described in the embodiments of this application. Figure 4 This is a front view (including the circular groove) of the cap-shaped busbar conductor described in the embodiments of this application. Figure 5 This is a front view (large size) of the bus conductor described in the embodiments of this application. Figure 6 This is a front view (small size) of the bus conductor described in the embodiments of this application. Figure 7 This is an exploded view of the busbar trunking.

[0021] In the figure: 1. Head; 2. Rod; 3. First positioning part; 4. Contact part; 41. Circular groove; 5. Metal shell; 51. Slot; 6. Connector; 61. Abutment part; 7. End cap; 8. Insulator. Detailed Implementation

[0022] To make the technical problems solved by this application, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of this application are further described in detail below. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0023] In the description of this application, unless otherwise expressly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0025] With the rapid development of artificial intelligence, big data, and the Internet of Things, the power demand of data centers continues to rise, and losses increase accordingly, leading to higher system operating temperatures. This places stringent demands on power supply security, reliability, and thermal efficiency. Rail-mounted busbar systems are increasingly widely used in data center power distribution due to their ability to optimize space utilization and control operating temperature and costs. Their core function is to distribute power to server racks using standard 3-meter-long busbars (often manufactured through extrusion and extended via connectors) paired with plug-in boxes (where the plugs are electrically connected to the busbar conductors), forming a critical power distribution link in the data center. However, due to limitations in structural design, manufacturing processes, and assembly logic, existing rail-mounted busbar systems and core conductor components still face numerous technical bottlenecks, making it difficult to meet the efficient, secure, and economical operational needs of data centers. Specific problems include: First, there is a significant conflict between heat dissipation efficiency and temperature rise control. Temperature rise is a core performance indicator for current-carrying conductors, directly determining their thermal efficiency, safety, and reliability. It is determined by both power loss and heat dissipation capacity. When current flows through a conductor, heat loss occurs due to resistance. Increased temperature further increases resistance, creating a vicious cycle of "temperature rise-loss." Excessive temperature not only exacerbates energy waste but also weakens the performance of component materials, leading to component failures and increased safety risks. 25%–55% of data center operating costs are spent on cooling systems, and 35%–55% of electricity is consumed in the cooling process. Therefore, a high-thermal-efficiency power distribution scheme is crucial for reducing cooling investment and optimizing operating costs.

[0026] In existing solutions, traditional busbar conductors often employ a uniform cross-section integrated structure. The core method for improving current carrying capacity and controlling temperature rise is to increase the conductor's cross-sectional area—reducing power loss by lowering resistance. However, this approach significantly increases the amount of conductor material used, weight, and manufacturing costs, while also expanding the overall volume of the busbar trunking, imposing stringent requirements on installation space, which contradicts the miniaturization and high-density power distribution needs of data centers. In contrast, improving heat dissipation performance is the optimal path for temperature control without increasing weight. However, existing uniform conductor structures have limited heat dissipation surface area, a single heat conduction path, and are prone to heat concentration at corners, resulting in low heat dissipation efficiency. Furthermore, the unreasonable design of the internal air chambers in the busbar trunking system further hinders heat dissipation, making it difficult to achieve a balance between heat dissipation and volume / cost.

[0027] Secondly, manufacturing processes are limited, making precision control of long-sized components extremely difficult. Existing standard busbar trunking lengths are mostly over 3 meters. These long components are typically manufactured using extrusion, but the characteristics of this process significantly restrict product structure and precision. On one hand, extrusion is difficult to manufacture components with complex shapes and sharp corners. Busbar trunking shells have relatively complex shapes, and sharp corners can easily cause pressure imbalances and stress concentrations, making dimensional accuracy difficult to control and hindering the stable mass production of high-quality busbar trunking. On the other hand, plastic materials, due to their poor dimensional stability and uneven cooling rates, are difficult to use for manufacturing insulators and other components via extrusion. Furthermore, long conductors, with their uniform, integrated structure, have an unreasonable rigidity distribution, making dimensional and positional tolerances (straightness, flatness, torsion angle, etc.) extremely difficult to control and prone to deformation. In addition, the quality of long components is easily compromised by external factors such as handling, storage, transportation, and vibration, further exacerbating manufacturing precision deviations.

[0028] Third, the cumulative effect of assembly tolerances leads to an uncontrollable and inefficient assembly process. Engineering components inherently have tolerances in their manufacturing, assembly, and installation. Longer components are more sensitive to these tolerances; the cumulative effect of deviations in straightness, wall thickness, and surface conditions significantly increases assembly difficulty, alters the final assembly result, reduces system performance, and increases safety risks. The existing busbar assembly logic is "insulators placed inside the shell, conductors pushed into the insulators," but the cumulative effect of tolerances in various components results in significant uncertainties in the assembly process: insulators are mostly made of soft materials with large geometric and positional deviations; conductors, due to their own form and position tolerances, have freedom of movement and orientation within the assembly gaps; the shell itself also has dimensional deviations, making it impossible to accurately predict the actual contact methods and contact surfaces between insulators and the shell, and between conductors and insulators.

[0029] The difficulty in calculating contact friction and the forces required for assembly leads to highly variable installation difficulty (ranging from easy to extremely difficult), making the assembly process completely uncontrollable. Excessive installation force can damage soft insulators, posing safety hazards; even minor defects in shape, size, or orientation of components can hinder assembly and reduce component functionality. Furthermore, to accommodate the fitting requirements of long components, larger assembly tolerances are necessary. While this reduces fitting difficulty, it increases the risk of components deviating from their intended position and orientation, altering contact and fit, and further affecting assembly accuracy. In addition, the unpredictability of assembly forces hinders the realization of automated assembly, increasing on-site commissioning procedures and operating costs.

[0030] Fourth, severe overheating in the contact area restricts power supply performance and safety. Performance failures in busbar systems are mostly concentrated in conductor contact areas (such as busbar trunking joints, and the connection points between the plug-in box's pins and the conductors). Multiple 3-meter busbar trunking sections are spliced ​​together to form long-distance power supply links. The plug-in box's pins form an electrical connection with the busbar conductors to supply power to IT loads. When current is conducted between the two contact surfaces, the contact resistance significantly increases power consumption and causes localized high temperatures, becoming the core pain point of system temperature rise. The magnitude of the contact resistance depends on the condition of the contact surfaces and the contact pressure, both of which are mainly determined by the position and orientation of the connection surfaces.

[0031] In existing busbar systems, the high contact resistance at joints poses a persistent risk of excessive temperature rise, component damage, and functional failure. The high contact resistance between the busbar conductors and the plug-in box also directly limits the maximum power supply capacity of the plug-in box. As mentioned earlier, the cumulative effect of existing assembly tolerances makes it difficult to precisely control the relative position and orientation of the conductors, insulators, and housing, further exacerbating the instability of the contact surface condition. This makes it impossible to achieve high-quality connections with low contact resistance, thus restricting the power supply performance of the busbar system and increasing safety risks.

[0032] To address the shortcomings of existing technologies, this embodiment provides a bus conductor, such as... Figures 1-6 As shown, it includes: an integrally formed head 1 and a rod 2, wherein the width of the head 1 is greater than the width of the rod 2, and at least the side of the head 1 facing away from the rod 2 has a smooth arc transition, and the rod 2 is also provided with a first positioning part 3.

[0033] Busbar trunking typically consists of busbar conductors, a metal casing, and an insulator. The busbar conductors are housed inside the metal casing, and the insulator is installed between the two to provide insulation. Addressing the technical shortcomings of traditional integrated, uniform busbar trunking structures, such as poor conductor heat dissipation and excessively large overall dimensions, this solution, based on the overall assembly logic of busbar trunking, designs the busbar conductors as a single-piece, non-uniform structure with a head 1 and a stem 2. By combining the positional characteristics of the head 1 with structural optimization, a significant improvement in heat dissipation efficiency is achieved. Because the head 1 is closer to the metal casing and the external environment than the rod 2, it is the core area for conductor heat dissipation. This solution directly increases the effective heat dissipation area of ​​the core heat dissipation region and widens the heat conduction path by designing the head 1 to be wider than the rod 2. At the same time, the smooth arc transition on the side of the head 1 away from the rod 2 eliminates the problem of heat concentration at the corners, allowing heat to be quickly conducted to the metal casing and the external environment along the arc surface, which greatly improves the overall heat dissipation efficiency of the conductor. The optimization of heat dissipation capacity means that the conductor does not need to increase its current carrying capacity by increasing its overall cross-section. The conductivity can be improved simply by optimizing the structure of the head 1. The rod 2 maintains a narrow structure to meet assembly requirements. The overall size and weight of the conductor are precisely controlled from the structural design, which completely solves the problems of excessive volume and weight and limited adaptability to narrow spaces caused by the increase in cross-section of traditional structures.

[0034] To address the shortcomings of traditional long, uniform conductor structures, such as high rigidity and shape / position control difficulties, high assembly deviations, and high debugging costs, this solution employs a dual design approach: Firstly, the non-uniform structure of the head 1 and the rod 2 optimizes the overall rigidity distribution of the conductor, altering the shape / position deformation patterns of traditional uniform long structures, reducing the difficulty of controlling the shape / position tolerances of long conductors, and minimizing structural deformation during assembly. Secondly, the first positioning part 3 in the rod 2 specifically forms positioning contact with the insulator of the busbar trunking. This precise positioning structure ensures accurate docking between the conductor, insulator, and metal shell, avoiding deviations at the assembly positioning level and guaranteeing conductor docking accuracy and conductive connection stability. Furthermore, the point / line contact of the positioning part replaces traditional surface contact, significantly reducing the contact area between the busbar conductor and insulator, lowering friction, and making the assembly of long conductors smoother, reducing on-site assembly debugging procedures and operating costs. In addition, the integrated design of the head 1 and the rod 2, while optimizing the non-uniform structure, ensures the overall structural strength and conductive continuity of the conductor, avoiding conductive connection losses in split structures, and balancing structural performance with core conductive performance.

[0035] This solution effectively solves the technical problems of poor conductor heat dissipation, excessive overall size, low assembly accuracy, and difficulty in assembling long sections in traditional busbar trunking by using an integrally molded head 1 and rod 2 with a non-uniform structure design, combined with the smooth arc transition of head 1, the first positioning part 3 of rod 2, and the overall assembly logic of the busbar trunking. This comprehensively improves the performance, assembly compatibility, and operational reliability of the busbar conductor and busbar trunking. Specific beneficial effects include: Firstly, leveraging the advantageous location of the heat dissipation core area of ​​the head 1, which is close to the external environment, the smooth arc transition of the head 1 (a near-circular, smooth structure) eliminates heat concentration at sharp corners, accelerates heat conduction to the metal casing and the external environment, and allows for increased material usage without increasing the conductor height. This maximizes current carrying capacity while maintaining conductor compactness, achieving triple optimization of heat dissipation, current carrying capacity, and size control. The improved heat dissipation efficiency allows for upgrading current carrying capacity without increasing the overall cross-section of the conductor. The narrow structure of the rod 2 effectively controls the volume and weight of the conductor and busbar, adapting to confined power distribution environments and aligning with the trends of miniaturization and high performance.

[0036] Secondly, the non-uniform structure optimizes the rigidity distribution of the conductor, reducing the difficulty of shape and position deformation and tolerance control for long conductors. The first positioning part 3 of the rod 2 precisely matches the insulator, and the smooth surface further reduces assembly friction, making the insertion of long conductors smoother and avoiding damage to the soft insulator. At the same time, the smooth surface can maintain a stable contact state during installation, reducing assembly deviations, significantly simplifying the debugging process, reducing operating costs and difficulty, facilitating automated assembly, and improving installation efficiency.

[0037] Third, the head 1 and the rod 2 are integrally molded, with a circular and smooth surface structure, which avoids the conductive loss and loosening risk of the split structure, and ensures structural strength, conductive continuity and electrical stability.

[0038] Fourth, the round and smooth surface ensures uniform pressure distribution during extrusion manufacturing and minimizes frictional resistance, significantly reducing the difficulty of extruding conductors and insulators, and adapting to the extrusion production needs of long-sized components. Reduced manufacturing difficulty effectively controls the defect rate, while also reducing mold wear, extending mold life, and lowering the overall cost of mass production. The overall structure retains the advantages of one-piece molding, simplifying processing steps, while optimizing the form to achieve a dual improvement in production efficiency and product qualification rate, thus balancing production and sales economics.

[0039] As an optional specific implementation, the positioning structure may not be provided on the rod 2 and the head 1.

[0040] Furthermore, the side surface of the rod 2 is flat. This design creates a regular planar structure on the side surface of the rod 2, which is suitable for the forming characteristics of the extrusion process. During processing, the force exerted by the mold on the rod 2 is evenly distributed, without stress concentration caused by uneven or curved structures. In the assembly and mating with the insulator, the contact surface between the flat side surface and the insulator is a regular plane, and the mating gap can be precisely controlled. It can form a synergistic positioning effect with the first positioning part 3 of the rod 2, and constrain the circumferential displacement of the conductor through planar contact. From the perspective of structural mechanics, the regular cross-sectional shape of the rod 2 with a flat side surface means that the stress is evenly distributed along the straight direction when under force, which optimizes the rigidity distribution of the rod 2 and reduces torsional and bending deformation in long-length states. At the same time, the flat side surface makes the current conduction path in the rod 2 regular and linear, without local current concentration areas caused by irregular side structure, ensuring the uniformity of current conduction in the rod 2.

[0041] In one optional embodiment, the outer contour of the head 1 is dome-shaped, and the connection point with the rod 2 is a rounded transition. The dome-shaped outer contour is a curved surface structure without sharp edges, which is suitable for the forming flow characteristics of the extrusion process. During manufacturing, the blank flows more smoothly in the mold, and the pressure is evenly distributed along the curved surface, without local stress concentration or frictional abrupt changes. In terms of heat dissipation, the dome-shaped curved surface significantly increases the effective heat dissipation contact area between the head 1 and the external environment, insulator, and metal shell, and heat can be evenly conducted along the curved surface without dead corners, avoiding heat accumulation at the edges. The rounded transition at the head-rod connection eliminates the heat conduction obstruction caused by structural abrupt changes, allowing the heat from the head 1 to be smoothly conducted and dispersed to the rod 2. In terms of electric field distribution, the dome-shaped outer contour has no sharp corners. Structurally, the rounded transition eliminates the structural angles at the head rod connection, fundamentally avoiding the concentration effect of electric field at sharp corners and angles, and reducing the local electric field intensity. From a structural mechanics perspective, the rounded transition disperses the stress concentration at the connection between the head 1 and the rod 2, allowing the stress to be evenly transmitted along the rounded surface when the conductor is under force, thus optimizing the structural rigidity at the head rod connection. From an assembly and fitting perspective, the overall smooth curved surface formed by the dome shape and the rounded transition makes the contact between the head 1 and the insulator and the shell a smooth surface contact, greatly reducing contact friction and scratching resistance during the assembly process, while avoiding scratches to the soft insulator by sharp structures.

[0042] The design of the head 1 with a dome-shaped outer contour and a rounded transition to the rod 2 focuses on the core function of the conductor head 1 and the structural characteristics of the head-rod connection, forming an independent and significant technical advantage. It adapts to all dimensions of requirements for busbar conductor manufacturing, heat dissipation, electrical safety, structural stability, and assembly compatibility. Its beneficial effects are as follows: This structure is fully compatible with the conductor extrusion molding process. The dome-shaped curved surface ensures more uniform flow of the blank within the mold, with pressure distributed along the curved surface without dead angles, eliminating local frictional abrupt changes and stress concentration problems. This not only significantly reduces the extrusion manufacturing difficulty of the head 1 and improves the dimensional accuracy and consistency of the head 1 molding, but also effectively reduces defects such as surface scratches and structural deformation during the manufacturing process. Simultaneously, it reduces local wear of the mold, extends mold life, and improves the economics of mass production. Heat dissipation efficiency is significantly optimized. The dome-shaped outer contour increases the effective heat dissipation area of ​​the head 1, allowing heat to be evenly conducted to the surrounding medium along the curved surface, completely eliminating the heat concentration problem of traditional angular structures. The rounded transition at the head-rod connection achieves unobstructed heat conduction between the head and rod, allowing heat from the rod 2 to flow smoothly to the head 1. Conductivity further enhances the overall heat dissipation efficiency of the conductor, providing structural support for increasing the current-carrying capacity of the conductor without increasing the overall cross-section; electrical safety performance is significantly improved, the dome-shaped outer contour avoids electric field concentration at sharp corners, and the rounded transition at the head rod connection eliminates electric field concentration points caused by structural angles, making the electric field distribution on the conductor surface more uniform, reducing the risks of corona and insulation breakdown caused by local high electric fields, and ensuring the operational stability of the conductor under high-voltage current-carrying conditions; assembly compatibility is further optimized, and the dome-shaped head and the rounded transition at the connection form a seamless whole. The smooth curved surface of the conductor significantly reduces the contact friction and scratching resistance between the head 1 and the insulator and metal shell during assembly, avoiding scratching and squeezing damage to the soft insulator caused by sharp structures. This makes it easier for the conductor to be pushed into the insulator, reducing the difficulty and force of assembly operations and improving assembly efficiency. At the same time, the dome-shaped structure can reasonably increase the amount of material used in the head 1 without increasing the overall installation height of the conductor, further improving the current carrying capacity of the conductor. It takes into account both the current carrying performance of the conductor and the compactness of the structure, which meets the requirements of miniaturized and high-density power distribution design of busbar trunking.

[0043] In another alternative design, the outer contour of the head 1 is hat-shaped, with an arc-shaped top side and vertically extending sides. The bottom of the sides extends horizontally towards the rod 2 and connects to the side of the rod 2. From a manufacturing perspective, although the hat-shaped structure is a combination of curved and planar forms, it has no sharp edges. The arc-shaped top side adapts to the flow characteristics of the extrusion process blank. The vertical side and horizontal connecting section can be precisely shaped by the mold, allowing the blank to flow evenly within the mold along the arc-shaped top side, vertical side, and horizontal connecting surface, resulting in balanced pressure distribution and no local frictional abrupt changes or stress accumulation. From a heat dissipation perspective, the arc-shaped top side increases the effective heat dissipation area of ​​the head 1, allowing heat to diffuse evenly along the arc surface, avoiding heat accumulation at sharp edges. The vertical side further expands the heat dissipation contact dimension. Combined with the horizontally extending connecting structure of the rod 2, the heat from the rod 2 is transferred to the vertical side via the horizontal connecting section and then smoothly introduced into the head 1 for dispersion, eliminating heat conduction barriers caused by structural abrupt changes. From a structural mechanics perspective, the horizontal... The top of the extended rod 2 forms a planar connection with the side of the head 1. Combined with the support of the vertical side, this significantly optimizes the stress distribution at the head rod connection, avoiding stress concentration as in traditional right-angle connections. At the same time, the overall hat-shaped structure makes the rigidity distribution of the head 1 more reasonable, enhancing its resistance to bending and torsional deformation. In terms of electric field distribution, the arc shape on the top side eliminates the hidden danger of electric field concentration at sharp corners, and the transition between the horizontal connection and the vertical side is without bends, so that the electric field on the conductor surface is evenly distributed along the arc-shaped top side and the vertical side, avoiding local electric field distortion. In terms of assembly, the smooth top side and regular vertical side of the hat-shaped outer contour reduce contact friction with the insulator and metal shell. The horizontal connection section forms a flat positioning surface, which can form a precise fit constraint with the insulator, improving the stability of assembly positioning.

[0044] The cap-shaped head 1 and its corresponding connecting structure design focus on the core functions of head 1 and the reliability of the head rod connection, forming an independent technical advantage that adapts to the needs of the entire life cycle of the busbar conductor. The beneficial effects are as follows: First, it adapts to extrusion manufacturing processes, improving mass production economy and precision. The top arc shape ensures smooth material flow, and the regular shape of the horizontal connection and vertical sides facilitates precise die processing. During extrusion, the pressure is uniform and friction is stable, reducing the difficulty of head 1 forming, minimizing manufacturing defects such as surface scratches and structural deformation, reducing localized die wear, extending die life, and improving the dimensional consistency of head 1, thus ensuring mass production. Second, it enhances heat dissipation efficiency, supporting increased current carrying capacity. The top arc shape and vertical sides work together to expand the effective heat dissipation area, combined with the continuous head rod heat dissipation path, significantly improving heat conduction and dissipation efficiency. Temperature rise can be reduced without increasing the overall conductor cross-section, providing structural support for upgrading current carrying capacity, while avoiding the volume expansion caused by increasing the cross-section in traditional structures, balancing high performance and compactness. Third, it optimizes structural mechanical properties, improving resistance to deformation. The horizontally extended connecting section and the vertical side form a stable support structure, effectively dispersing stress concentration at the head rod connection point and preventing conductor cracking and deformation during processing, transportation, assembly, and stress conditions. Simultaneously, the overall cap-shaped structure enhances the rigidity of the head, suppresses dimensional deviations in long conductors, reduces the difficulty of controlling tolerances such as straightness and flatness, and ensures structural integrity and service life. Fourth, it optimizes the electric field distribution and improves electrical safety. The top-side arc-shaped and angle-free connection design completely avoids electric field concentration caused by sharp corners and structural abrupt changes, resulting in a uniform electric field distribution on the conductor surface, reducing the risks of corona discharge and insulation breakdown, adapting to high-voltage current-carrying conditions, and enhancing the operational stability of the busbar conductor. Fifth, it improves assembly adaptability and reduces operational difficulty. The smooth top side reduces assembly friction and avoids scratching the soft insulator. The flat surface formed by the horizontal connecting section fits precisely with the insulator, which can work with the positioning part of the rod to improve the assembly positioning accuracy and constrain the circumferential and axial displacement of the conductor. At the same time, the regular vertical side makes it easy to adapt to the housing cavity of the bus trunking and the insulator. While maintaining a compact structure, it improves the assembly stability and meets the needs of miniaturization and easy assembly of data center bus trunking.

[0045] Crucially, compared to traditional strip-shaped or T-shaped conductors, under the same current conduction conditions, the dome-shaped head can achieve a heat dissipation area of ​​94,800 mm². 2 The heat dissipation rate reaches 403%, and the heat dissipation area of ​​the cap-shaped head can reach 92,400 mm². 2 The heat dissipation rate reaches 390%; while the heat dissipation area of ​​the head 1 of the strip-shaped conductor is only 18840 mm². 2 The heat dissipation area of ​​the head of the T-shaped conductor is only 66900 mm². 2The heat dissipation efficiency is only 255%, indicating that the circular shape of our conductor provides more heat transfer surface area in the high heat dissipation area of ​​the casing. Therefore, the circular shape increases the effective heat transfer area of ​​the conductor. The increased heat transfer efficiency and reduced operating temperature maximize heat dissipation efficiency and enhance safety. Traditional strip and T-shaped busbar conductor heads are regular planar or simple folded structures. The heat transfer surface is limited by the planar geometry and has a low fit with the high heat dissipation area of ​​the busbar casing. Heat transfer can only be achieved through local planes, which greatly limits the effective heat transfer area. At the same time, this type of structure requires increasing the cross-sectional area to increase the conductivity, further compressing the optimization space of the heat dissipation surface. The dome-shaped or hat-shaped head 1 of this solution uses a curved surface as its core structural form. While maintaining the same current conductivity and without increasing the overall cross-sectional area of ​​the conductor or the space occupied, it breaks through the heat transfer area limitations of traditional planar structures. The geometric characteristics of the curved surface significantly expand the solid heat transfer surface of the head 1. Furthermore, the curved structure precisely matches the high heat dissipation area of ​​the busbar casing, allowing the heat transfer surface of the conductor head 1 to fully contact the surrounding heat dissipation medium (insulator, metal shell), maximizing the utilization of the heat transfer conditions in the high heat dissipation area of ​​the casing, avoiding ineffective waste of heat transfer surface, and achieving a leapfrog increase in effective heat transfer area. In addition, the curved structure eliminates the problem of heat concentration at sharp corners. The increased effective heat transfer surface allows heat to be uniformly and quickly conducted along the curved surface to the high heat dissipation area of ​​the casing. From the three dimensions of increasing the effective heat transfer area, adapting to the high heat dissipation area, and optimizing the heat conduction path, a significant improvement in heat dissipation rate is achieved. Ultimately, under the same current conductivity, it directly reduces the conductor operating temperature, rather than the passive design approach of traditional solutions that rely on increasing the cross-sectional area to increase current carrying capacity.

[0046] Furthermore, in a three-phase AC busbar system, the conduction of current generates an electromagnetic force due to electromagnetic induction. Under normal operating conditions, this electromagnetic force has a small amplitude, causing only slight reciprocating traction and pushing of the conductor, which does not affect system operation. However, when a short-circuit fault occurs, the short-circuit current can reach tens of times the rated current, causing the electromagnetic force to amplify dramatically on a quadratic scale, forming a strong impact force sufficient to permanently deform the conductor and damage the busbar system structure. Traditional strip and T-shaped conductors have their material distribution concentrated in a fixed cross-section, resulting in insufficient material in the area where the electromagnetic force acts. This leads to a small structural moment of inertia, making it difficult to resist the instantaneous impact of the short-circuit electromagnetic force, and making them prone to permanent deformation such as bending and twisting.

[0047] This solution utilizes a circular conductor structure with optimized material distribution. The material is increased along the circular contour in the conductor's width direction, and this additional material is precisely distributed in the primary area affected by short-circuit electromagnetic forces. From a structural mechanics perspective, this significantly enhances the conductor's moment of inertia and section modulus in this region, strengthening its resistance to bending, tension, and torsional deformation. Simultaneously, the circular structure distributes stress evenly, dispersing the instantaneous impact electromagnetic force along the surface and preventing stress spikes caused by localized stress concentrations, further reinforcing resistance to deformation. Combined with high-strength conductor materials, whose excellent tensile strength, yield strength, and elastic modulus synergize with the optimized material distribution of the circular structure, this solution constructs a highly efficient resistance system to short-circuit electromagnetic force deformation from both structural reinforcement and material enhancement dimensions, maximizing the mitigation of the impact of strong electromagnetic forces during short circuits.

[0048] The design of a circular conductor structure combined with high-strength materials specifically addresses the core risk of electromagnetic force damage during short circuits in busbar systems, resulting in significant technological advantages. The beneficial effects are as follows: First, it greatly enhances the conductor's resistance to deformation caused by short-circuit electromagnetic forces. The increased material volume in the electromagnetic force application area due to the circular structure, combined with the mechanical properties of the high-strength materials, significantly increases the conductor's resistance threshold to instantaneous strong electromagnetic force impacts. This effectively resists extreme electromagnetic forces during short circuits, preventing permanent deformation, breakage, and structural damage to the busbar system, thus preventing the cascading damage of short-circuit faults at the core structural level. Second, it ensures the structural integrity of the busbar system after a short circuit, reducing the risk of fault escalation. Compared to the tendency of traditional conductors to fail after a short circuit, this design allows the conductor to maintain its basic structure and conductivity after a short circuit, reducing the extent of the fault and lowering the risk of overall power distribution system outages due to busbar damage. Third, it strengthens the operational safety and reliability of the busbar system. By suppressing structural failure caused by short-circuit electromagnetic forces at the source, it significantly reduces insulation damage, secondary short circuits, and other derivative damage caused by short-circuit faults. The design addresses several key concerns: First, it provides core electromagnetic and mechanical safeguards for the long-term stable operation of the busbar system, particularly suitable for scenarios with extremely high power supply continuity requirements, such as data centers. Second, it offers enhanced efficiency through synergistic structural and material improvements, resulting in superior cost-effectiveness. The circular structure enhances deformation resistance through rational material distribution, eliminating the need for excessively large conductor volumes. This balances structural compactness with impact resistance. Combined with high-strength materials, it achieves a significant leap in short-circuit resistance performance compared to traditional solutions that rely solely on increasing cross-sections, while controlling cost and weight. Third, it extends the service life of the busbar system, reducing maintenance costs. It avoids frequent maintenance work such as conductor replacement and system overhaul due to short-circuit electromagnetic deformation, lowering the overall lifecycle maintenance cost and reducing downtime, thus improving the operational efficiency of the power distribution system. Fourth, it adapts to high-load power distribution scenarios. The combination of high strength and the circular structure allows the busbar conductor to withstand higher rated currents and short-circuit currents, expanding the product's application range in high-load power distribution scenarios such as industrial and data centers, further enhancing product competitiveness.

[0049] In some embodiments, the first positioning part 3 is a positioning groove provided on the side of the rod 2, and the positioning groove extends along the length direction of the rod 2. The first positioning part 3 adopts a side positioning groove structure extending along the length direction of the rod 2. By forming a concave-convex mating positioning mechanism with the positioning protrusion on the insulator, a precise assembly constraint system for the conductor and the insulator is constructed, while optimizing the contact characteristics and heat conduction path. The specific working principle is as follows: The matching design of the positioning groove and the positioning protrusion limits the contact range between the conductor and the insulator. Contact is achieved only through the mating characteristics of the two (groove wall and protrusion surface), replacing the traditional surface contact mode. The contact area is precisely controlled structurally, so that the minimum contact surface between the conductor and the insulator is minimized, thereby significantly reducing the contact friction resistance during the assembly process. According to the inverse relationship between pressure and contact area, the reduction of the contact surface can greatly increase the installation pressure of the mating area under the premise of constant force applied during assembly. Under high pressure, the positioning groove and the positioning protrusion form a tight fit, and the mating groove and the positioning protrusion form a tight fit. The rigid contact with the combined features effectively constrains the conductor and insulator's degrees of freedom in position (axial, radial) and direction (circumferential, angular), significantly reducing assembly deviations and ensuring consistent contact states. Consistent contact states and stable high voltage provide predictable assembly forces and positioning benchmarks for automated assembly, avoiding the problems of unknown contact methods and uncontrollable assembly forces encountered with traditional soft insulators and conductors. Simultaneously, precise fit allows for minimizing the assembly gap between the conductor and insulator, significantly reducing air cavities in the mating area (air is a poor conductor of heat), lowering thermal resistance from air cavities, and accelerating heat transfer and heat dissipation efficiency. Furthermore, the positioning groove, through the insulator's positioning protrusions, firmly constrains the conductor in a preset position and direction, preventing electrical contact misalignment caused by conductor displacement, ensuring precise docking of the conductor with plug-in box components such as pins and connectors, and optimizing electrical contact performance.

[0050] The design of the positioning grooves on the two sides of the pole, which mate with the positioning protrusions on the insulator, specifically addresses the problems of high friction, inconsistent contact, large deviations, numerous air cavities, and difficulties in automated assembly in traditional busbar conductor-insulator assembly. This results in multi-dimensional technical advantages, with the following benefits: First, it optimizes assembly characteristics, reduces operational difficulty, and adapts to automation. Minimizing the contact surface significantly reduces assembly friction. Combined with the tight fit provided by high voltage, this makes the process of pushing the conductor into the insulator smoother, preventing damage to the soft insulator due to excessive friction. Simultaneously, consistent contact and predictable assembly force provide stable operating conditions for automated assembly, reducing the debugging difficulty of automated equipment and improving assembly efficiency and consistency. Second, it improves assembly positioning accuracy and reduces the risk of deviation. The interlocking fit between the positioning grooves and the positioning protrusions structurally limits the positional and directional deviations of the conductor and insulator. Combined with the clamping effect of high voltage, this ensures that the two always maintain the correct relative position and contact posture, completely changing the situation of unknown contact methods and uncontrollable deviations in traditional assembly, and guaranteeing the stability of assembly quality. Third, it enhances heat dissipation efficiency and optimizes the heat transfer path. Minimizing assembly gaps significantly reduces air cavities in the mating area, lowers thermal resistance, and allows heat generated by the conductor to be quickly transferred to the insulator through contact characteristics, and then conducted to the busbar housing for dissipation. This significantly improves heat flow efficiency and overall heat dissipation performance, providing support for conductor low-temperature operation. Fourth, it improves electrical contact performance and ensures power supply stability. The conductor is firmly constrained by the insulator in a preset position and orientation, avoiding problems such as electrical contact misalignment and uneven contact pressure caused by conductor offset. This effectively reduces the contact resistance between the conductor and the plug-in box, connectors, and other parts, reducing the risk of localized heating, improving the reliability and stability of electrical contacts, and ensuring the current-carrying capacity of the busbar system. Fifth, it enhances the integrity of component mating and overall performance. Stable high-voltage strong contact and precise positioning significantly improve the tightness of the fit between the conductor and the insulator, reducing the risk of assembly loosening and extending the service life of the components. At the same time, the reduction of assembly gaps and air cavities further optimizes the structural compatibility of the conductor and insulator, avoiding vibration, noise, and performance degradation caused by excessive gaps, and comprehensively improving the operating performance of the busbar components.

[0051] Specifically, the positioning groove is V-shaped and recessed into the side of the rod 2. The two inclined surfaces of the V-groove are symmetrically distributed at an included angle. During assembly, the positioning protrusion of the insulator can achieve self-centering guidance along the inclined surface, automatically correcting slight positional deviations between the conductor and the insulator, and guiding the protrusion to slide precisely into the bottom of the groove to form a fitting fit. Compared with planar or arc-shaped positioning grooves, the contact between the V-groove and the protrusion is a line contact (rather than a surface contact), which can precisely define the contact range in the structure, minimize the contact surface, and further reduce assembly friction resistance. According to the pressure formula, while the contact area is precisely reduced, the V-shaped inclined surface can decompose the assembly force into a component force along the inclined surface and a component force perpendicular to the contact line. Positive pressure concentrates the pressure on the contact wire area, significantly increasing the installation pressure at the mating parts; the bidirectional symmetrical inclined plane forms a circumferential bidirectional constraint, which can effectively limit the torsional deformation and radial displacement of the conductor around the axis of the rod part 2. Combined with the high pressure clamping effect, it further reduces the space for deviation between the conductor and the insulator in position and direction; the tight line contact of the V-groove can eliminate the mating gap to the maximum extent, reduce the formation of air cavities in the gap, and reduce thermal resistance. At the same time, the rigid support of the V-shaped structure can firmly constrain the conductor in the preset posture, avoiding the impact of contact displacement on the electrical contact accuracy.

[0052] In addition, the head 1 is provided with the first positioning part 3, which is a positioning groove located at the top of the head 1 and extends along the length of the head 1. The positioning groove extending along the length of the head 1 ensures that the contact between the conductor and the insulator covers the entire length of the head 1, rather than a local contact. The contact surface is a line contact or narrow surface contact between the groove wall and the protrusion, precisely defining the contact area and minimizing the contact area between the two. Based on the inverse relationship between pressure and contact area, the installation pressure in the contact area is significantly increased under constant assembly force. The groove structure extending the entire length has natural guiding properties, allowing the insulator protrusion to slide smoothly into the groove during assembly, automatically correcting slight axial and circumferential deviations between the conductor and the insulator, and guiding them to form precise alignment. As the core area for current carrying and heat dissipation of the busbar conductor and a key part for structural adaptation, the top positioning groove forms a rigid constraint from above the head 1, which can effectively limit the displacement of the conductor in the vertical direction and the rotation around the axis of the rod part 2. The torsional deformation, along with the positioning structure of rod 2 (if any), forms a synergistic positioning effect, constructing a three-dimensional constraint system, which significantly reduces the space for positional and directional deviations between the conductor and the insulator; the tight fit between the groove and the protrusion minimizes the assembly gap between the head 1 and the insulator, reducing the formation of air cavities (poorly heated conductors) within the gap, and the extension of the groove along its length does not damage the core heat dissipation surface (dome-shaped / hat-shaped outer contour) of the head 1, and does not affect the original heat dissipation path of the head 1. At the same time, the high-pressure and strong fit ensures that heat can be quickly transferred through the mating surface; in addition, the constant mating characteristics throughout the entire length make the contact state uniform and consistent, and the assembly force is highly predictable, providing a stable positioning reference and force condition for automated assembly, avoiding the problems of unknown contact methods and uncontrollable deviations in the traditional assembly of head 1.

[0053] The positioning groove design extending along the length of the top of the head 1, based on the basic function of the first positioning part 3, combines the core functional characteristics of the head 1 to form a unique technical advantage. It enhances positioning and assembly performance without compromising the heat dissipation and current-carrying core performance of the head 1. The beneficial effects are: First, it optimizes assembly convenience and adapts to automated operations. The full-length extended groove has a guiding function, guiding the insulator protrusion to slide precisely along the axial direction. Combined with the reduced frictional resistance due to the smaller contact area, the assembly of the head 1 and the insulator is smoother, preventing damage to the soft insulator due to uneven local force or excessive friction. Simultaneously, uniform contact along the entire length provides stable and predictable assembly force, eliminating uncertainties in the assembly process and ensuring continuous automated assembly operations, improving assembly efficiency and consistency. Second, it constructs three-dimensional positioning constraints, improving geometrical accuracy. The top positioning groove of Head 1 forms a rigid constraint on the conductor from above, effectively limiting the conductor's vertical displacement and circumferential torsional deformation. When used in conjunction with the positioning structure of Rod 2, it can construct a three-dimensional positioning system of "Head 1-Rod 2," significantly reducing the overall position and orientation deviation of the conductor, ensuring accurate conductor posture after assembly, and solving the problems of easy displacement and poor fit of Head 1 in traditional assembly, thus guaranteeing the overall assembly accuracy of the busbar assembly. Thirdly, it ensures the heat dissipation efficiency of Head 1 and optimizes heat transfer. The groove extends along its length without disrupting the dome / hat-shaped core heat dissipation surface of Head 1, maximizing the retention of the effective heat dissipation area of ​​Head 1. At the same time, the tightly fitted, reduced air cavity lowers thermal resistance, allowing the heat generated by Head 1 to dissipate through the curved surface and be quickly conducted through the mating surface between the positioning groove and the insulator, achieving complementary heat dissipation paths without affecting the original heat dissipation advantages of Head 1. Fourthly, it stabilizes electrical contact performance and enhances power supply reliability. The precise constraint of the head 1's posture ensures accurate docking with components such as busbar trunking connectors and plug-in boxes, preventing issues like misalignment and uneven contact pressure caused by head 1 offset. Simultaneously, the high-voltage, uniform contact stabilizes contact resistance, reducing the risk of localized heating and further enhancing the stability and current-carrying capacity of the busbar system's electrical contacts. Fifth, it adapts to the structural characteristics of head 1, ensuring rigidity and molding precision. The regular groove structure extending along its length can be integrally extruded with head 1 without weakening its overall rigidity. It also adapts to dome-shaped, hat-shaped, and other outer contours of head 1, preventing damage to the curved surface integrity due to positioning structure settings. The consistent dimensions of the groove along its length are easily controlled, meeting the mass production requirements of extrusion processes, resulting in a low molding defect rate. Furthermore, uniform mold wear extends mold life, balancing structural performance and mass production economics. Sixth, it improves component fit and reduces operational risks. The tight fit along the entire length significantly improves the fit between the head 1 and the insulator, reducing the risk of loosening caused by external factors such as vibration and transportation. At the same time, minimizing the assembly gap can prevent impurities from entering, reduce the risk of insulation damage, extend the service life of the busbar assembly, and comprehensively improve operational reliability.

[0054] In one embodiment, the bottom side of the rod 2 is provided with a contact portion 4 that can make contact with the plug claw of the plug box and conduct electricity. Contact portion 4, as a specifically designed conductive functional area, clearly defines the contact points and contact area between the conductor and the claw, ensuring that the claw can accurately act on this area when clamping or abutting, avoiding poor current conduction caused by contact position misalignment. By optimizing the surface morphology of contact portion 4 to adapt to the claw structure, the effective contact area between contact portion 4 and the claw can be increased. At the same time, relying on the overall positioning structure of the conductor to precisely constrain the conductor's posture, it ensures that contact portion 4 and the claw always maintain the preset contact pressure and alignment accuracy, reducing contact resistance fluctuations. During current conduction, contact portion 4 concentrates the current transfer between the claw and the conductor, making the current path regular and avoiding excessively high local current density caused by contact dispersion. In the face of strong electromagnetic forces during short circuits, contact portion 4 on the bottom side of rod 2, together with the rigid structure and positioning constraints of rod 2, can resist conductor displacement or claw misalignment caused by electromagnetic forces, maintaining a stable contact state. At the same time, the tight contact state of contact portion 4 can form a heat conduction path, quickly conducting the Joule heat generated in the contact area to the main body of rod 2, and then dissipating it through the heat dissipation structure of head 1, avoiding local heat accumulation.

[0055] Optionally, such as Figure 2 As shown, the contact portion 4 includes two inclined sides sloping downwards from the outside to the inside, with their bottom ends intersecting. This double-inclined structure breaks the area limitation of traditional planar contact, extending the inclined surfaces to form a larger effective contact area. This allows the plug-in box's claws to form a close contact with the two inclined sides when gripping or abutting, significantly increasing the conductive contact area compared to a single planar contact. The outward-to-inward sloping shape guides the claws to precisely fit the contact area, and combined with the conductor positioning structure's constraint on the conductor's posture, ensures a uniform distribution of contact pressure between the claws and the inclined sides, avoiding incomplete local contact. The intersection of the bottom ends of the contact portion 4 can be machined to form a flat connecting surface, adapting to the planar connection requirements of the conductor ends, thus retaining the additional contact surface extended by the inclined sides. Furthermore, the bottom plane ensures rigid contact during conductor docking, allowing current to be conducted over a large area through the inclined side and stably transmitted through the bottom plane, achieving redundant protection for contact conduction. During current conduction, the expanded contact area evenly distributes the current density, avoiding Joule heating surges caused by local current concentration. At the same time, the larger contact area creates an efficient heat conduction path, which can quickly conduct heat from the contact area to the main body of the rod. In addition, the symmetrical structure formed by the inclined side has the ability to distribute force, resisting the impact of short-circuit electromagnetic forces and assembly vibrations on the contact state, and maintaining contact stability in conjunction with uniform contact pressure.

[0056] The four-double-beveled structure of the contact section addresses the problems of insufficient contact area, high contact resistance, and low connection accuracy associated with traditional planar contact by expanding the contact surface, optimizing the contact shape, and improving processing adaptability. It works synergistically with the overall conductor structure, resulting in the following benefits: First, it significantly expands the effective contact area and improves contact quality. The double-beveled structure further expands the conductive contact area. Combined with the plane processed at the bottom intersection, it forms a composite contact shape of bevels and planes. Compared to traditional single-plane contacts, the contact area is greatly increased, significantly reducing contact resistance and Joule heating in the contact area. It also avoids problems such as localized high temperatures and electrical contact failure caused by insufficient contact area, ensuring contact performance stability from a structural perspective. Second, it optimizes current conduction characteristics and improves current carrying capacity. The expanded contact surface ensures a uniform current density distribution along the bevels and the bottom plane, avoiding additional power losses caused by localized current concentrations. The stable contact state reduces contact resistance fluctuations, making current transfer between the connector pins and the conductor smoother. This effectively breaks through the limitations of traditional contact structures on the maximum power supply capacity of the pins, increasing the upper limit of the bus system's current carrying capacity. Third, it adapts to processing and docking requirements, ensuring reliable connection. The intersection of the bottom ends of contact part 4 can be easily processed into a flat plane, perfectly adapting to the process requirements of flat connection of conductor ends. It retains the advantage of the beveled side expanding the contact surface, while ensuring the positioning accuracy and rigid contact during conductor docking through flat processing, avoiding poor contact caused by sharp point contact, and achieving the dual requirements of large-area conduction and precise docking. Fourth, it enhances assembly adaptability and positioning accuracy. The double beveled shape with an outward to inward inclination has natural guiding properties, which can guide the plug-in box claws to quickly and accurately fit the contact area. Combined with the overall positioning structure of the conductor, it further improves the docking accuracy of the claws and contact part 4, reduces assembly deviation, and the evenly distributed contact pressure makes the assembly force easier to control, adapting to the requirements of automated insertion and removal operations. Fifth, it improves anti-interference and structural stability. The symmetrical inclined structure can disperse the impact of short-circuit electromagnetic force and vibration, avoid misalignment or damage caused by excessive local stress at the contact point, and at the same time, the enlarged contact surface enhances the structural rigidity of the contact part 4, reduces contact deformation during long-term use, extends the service life of the contact part 4, and ensures the operational stability of the bus system under complex working conditions.

[0057] Preferably, such as Figure 3 and Figure 4As shown, the contact portion 4 includes two inclined edges that slope upwards from the outside to the inside, and a circular groove 41 connecting the tops of the two inclined edges. This structure is a dedicated design for adapting to round / pointed prongs. The double inclined edges, sloping upwards from the outside to the inside, have natural guiding characteristics, allowing the prongs to slide smoothly along the inclined edges during insertion. When the prongs contact the insulator, the inclined structure of the edges generates a lateral pushing force, pushing the insulator to the side to avoid interference from the insulator, ensuring that the prongs move forward unimpeded to the preset contact position. The circular groove 41 at the top is a customized receiving structure for the prong tip. Its curved shape precisely matches the prong tip, allowing the prong tip to be completely embedded in the groove. Structurally, this forcibly prevents the prong tip from forming point / line contact with the conductor, forcing... The sides of the prongs make close contact with the inclined surfaces of the double bevels, maximizing the conductive contact area. At the same time, the connection structure between the circular groove 41 and the double bevels provides rigid constraints on the position and orientation of the prongs, precisely limiting the relative posture between the prongs and the conductor, and keeping the prongs firmly in the preset optimal contact position, avoiding contact displacement caused by vibration, electromagnetic force, or other factors after insertion. In addition, the large-area contact between the sides of the prongs and the double bevels allows the current to be evenly conducted along the inclined surfaces, dispersing the current density in the contact area, while also constructing an efficient heat conduction path to quickly dissipate the Joule heat generated in the contact area and prevent local heat accumulation.

[0058] The combined structure of contact part 4 is custom-designed for both circular / pointed claws and plug-in box claws, specifically addressing issues such as plug-in interference, small contact area, easy overheating of pointed contacts, and easy contact posture deviation inherent in traditional contact structures. It works synergistically with the overall conductor structure to create significant technical advantages, with the following benefits: First, it precisely adapts to the circular / pointed claws, completely eliminating plug-in interference. The double beveled edges, sloping upwards from the outside to the inside, provide smooth plug-in guidance and allow for active avoidance of the insulator through lateral pushing, ensuring the claws advance unimpeded to the preset position without requiring additional insulator clearance processing. This simplifies the insulator structure design while improving the smoothness of plug-in assembly and reducing the difficulty of on-site assembly and automated plug-in / plug-out operations. Second, it maximizes the conductive contact area, significantly reducing contact resistance. The circular groove 41 constrains the tip of the prong, forcing a large-area surface contact between the prong's side and the double bevels, replacing traditional point / line contact. This significantly increases the effective conductive contact area, reduces contact resistance at the structural level, minimizes Joule heating in the contact area, and avoids problems such as localized high temperatures and electrical contact failure caused by point contact, thus improving the stability of current conduction. Thirdly, it precisely constrains the contact posture, maintaining optimal contact performance. The connection structure between the circular groove 41 and the double bevels rigidly positions the prong, firmly holding it in the preset optimal contact position. This effectively resists interference from external factors such as short-circuit electromagnetic forces and equipment vibration, preventing contact posture shift after insertion, ensuring the stability of contact pressure and contact area, and achieving long-term reliable electrical contact. Fourthly, it optimizes current and thermal conduction characteristics, improving current carrying capacity and thermal stability. Large-area surface contact allows for uniform current distribution along the double-hedged sides, dispersing current density, reducing additional power loss, and breaking through the limitation of traditional tip contact on the maximum power supply capacity of the plug-in box, thereby increasing the upper limit of the current carrying capacity of the bus system. Simultaneously, the large-area contact creates an efficient heat conduction path, rapidly transferring Joule heat from the contact area to the main body of the rod 2, and then dissipating it through the heat dissipation structure of the conductor head 1. Combined with the overall conductor heat dissipation system, this further reduces the temperature rise of the contact part 4, delays insulator aging, and improves electrical safety performance. Fifth, the structure has strong adaptability, taking into account the design rationality of both the insulator and conductor. This structure does not require changes to the core structural dimensions of the conductor and insulator; plug-in adaptation is achieved only through the morphological optimization of the contact part 4. This preserves the structural integrity and insulation protection performance of the insulator without compromising the overall rigidity and molding processability of the rod 2, achieving synergistic optimization of the conductor and insulator. Sixth, it improves assembly consistency and mass production economy. The guiding, avoidance, and positioning functions of the contact part 4 are all achieved by the structure itself, eliminating the need for precise manual alignment, which greatly improves the consistency of the plug-in assembly and meets the needs of automated plug-in and unplugging operations. At the same time, the combined structure has a regular geometric shape and can be integrally extruded with the rod part 2, making it easy to control dimensional accuracy, resulting in a low molding defect rate, uniform mold wear, and extended mold life, thus balancing mass production efficiency and manufacturing costs.

[0059] Furthermore, the conductive contact point with the plug is exclusively limited to the bottom of the conductor. This ensures sufficient contact surface at the bottom to meet the conductive contact area requirements between the plug and the conductor, replacing the traditional side contact mode. This eliminates the need for a pre-reserved adaptation cavity for side plug connections from the design stage. The elimination of side connection cavities directly reduces the total amount of air cavity inside the busbar trunking. Since air is a poor conductor of heat, the reduction in air cavity significantly lowers the thermal resistance between the conductor and the insulator and metal casing. This allows heat generated by the conductor to be quickly conducted to the insulator through the bottom contact surface and then smoothly transferred to the metal casing for dissipation. Simultaneously, the conductor and surrounding... The components have a more complete contact and a more continuous heat conduction path, achieving a dual improvement in heat conduction efficiency and overall heat dissipation efficiency. In addition, the structural design without reserved cavities on the side ensures that the conductor itself has no redundant space to avoid, and the insulator and metal shell do not need to make structural avoidance and space reservation for the side cavity. The cooperation between the conductor and the insulator and metal shell can achieve a precise fit without redundant space. The efficient use of space from the individual conductor to the busbar trunking achieves a compact structural design. Furthermore, the design of sufficient contact surface at the bottom does not sacrifice the effective contact area between the conductor and the plug, and does not affect the core performance of current carrying and conductivity.

[0060] In practical applications, the width of the head 1 is 6-12mm, the width of the rod 2 is 3-6mm, the height of the head 1 is 8-12mm, and the height of the rod 2 is 10-16mm. This size ratio is precisely set based on the functional differences between the conductor head 1 and the rod 2. The head 1, as the core area for heat dissipation and current carrying, is designed with a width of 6-12mm to adapt to the dome / hat-shaped curved surface structure, maximizing the effective heat dissipation area and current carrying cross-sectional area. The height of 8-12mm precisely controls the radial space occupied by the conductor, avoiding the overall volume expansion of the busbar trunking due to excessive height. The rod 2, as the functional area for assembly positioning and contact conductivity, has a narrow width of 3-6mm to minimize the contact area with the insulator and reduce assembly friction. The height of 10-16mm, slightly higher than the head 1, is designed to adapt to the docking posture of the bottom contact part 4 of the rod 2 and the plug-in box claw, ensuring the contact pressure and contact area between the claw and the contact part 4, while reserving sufficient geometric space for the structural design of the positioning groove of the rod 2 and the contact part 4. The defined size ranges of 6-12mm and 3-6mm strictly match the forming accuracy threshold of the extrusion process. Sizes within this range are within a reasonable range easily achievable by the extrusion process, effectively controlling dimensional deviations during forming and ensuring product consistency. Simultaneously, the dimensional difference between head 1 and rod 2 creates a non-uniform structure, optimizing the overall rigidity distribution of the conductor and preventing torsional and bending deformation of long conductors. Furthermore, the height of rod 2, the height and width of head 1 support fine-tuning based on load-bearing capacity while minimizing dimensional changes. According to the current-carrying requirements of different power distribution scenarios, the current-carrying cross-sectional area can be gradually adjusted without altering the overall conductor structure. This achieves precise matching of load-bearing capacity while avoiding damage to the original heat dissipation, positioning, and contact structure design advantages due to large dimensional adjustments, while keeping the increase in conductor volume and weight to a minimum. The fixed-length design of head 1 and rod 2 also precisely matches the internal space of the insulator housing and busbar trunking shell, making the assembly gap controllable. This avoids conductor misalignment due to excessive gaps or assembly difficulties due to excessively small gaps, while minimizing air cavities within the mating gaps and improving heat conduction efficiency.

[0061] The fixed-length range design and minimization-based micro-adjustment mechanism of the head 1 and rod 2 achieve comprehensive optimization in function, process, assembly, and scenario adaptation, forming a synergistic effect with the overall conductor structure. Its independent beneficial effects are reflected in the following: First, precise matching of size proportions and functional zoning enhances core performance. The wide design of the head 1 maximizes heat dissipation and current carrying capacity, adapting to the heat dissipation advantages of the dome / hat-shaped curved surface. The narrow rod 2 reduces assembly friction and adapts to the positioning groove structure. The slightly higher height of the rod 2 compared to the head 1 ensures the docking accuracy and contact pressure between the contact part 4 and the plug-in box claws. The dimensions of each part serve the function, achieving a balance in heat dissipation, current carrying capacity, assembly, and conductivity. Second, the size range matches the characteristics of the extrusion process, improving mass production accuracy and economy. The fixed-length ranges of 6-12mm and 3-6mm strictly match the forming threshold of the extrusion process. Within this range, the forming difficulty is low, and dimensional deviations are easy to control, significantly improving product forming consistency and reducing manufacturing defects. At the same time, the reasonable size design ensures uniform mold wear, extends mold life, and balances the accuracy requirements and manufacturing costs of mass production. Third, non-uniform dimensions optimize structural rigidity and reduce the difficulty of controlling form and position deviations. The non-uniform structure formed by the difference in width and height between the head 1 and the rod 2 optimizes the overall rigidity distribution of the conductor, effectively resisting torsional and bending deformations of long conductors during processing, transportation, and assembly, improving the control accuracy of form and position tolerances such as straightness and flatness, and reducing assembly deviations. Fourth, a minimal size fine-tuning mechanism enhances scenario adaptability while retaining structural advantages. The width and height dimensions of the head 1 and the rod 2 can be adjusted according to different load-bearing capacity requirements, with minimal dimensional changes. This achieves precise matching of current-carrying capacity with power distribution scenarios without altering the overall structural form of the conductor, fully preserving the structural design advantages of the original positioning, heat dissipation, and contact part 4, while keeping the increase in conductor volume and weight to a minimum, ensuring the compactness of the busbar trunking and adapting to power distribution needs of different power levels. Fifth, fixed-length design adapts to the assembly system, improving assembly and heat dissipation stability. The dimensions of the head 1 and the rod 2 are precisely matched with the insulator cavity and the busbar housing, keeping the assembly gap within a controllable range. This avoids conductor position displacement caused by excessive gaps, and assembly obstruction caused by excessive gaps. Simultaneously, the minimized fit gap reduces the formation of air cavities, lowers thermal resistance, improves heat conduction efficiency between the conductor and the insulator / housing, and enhances overall heat dissipation performance. Sixth, the dimensional design provides ample space for each functional structure, ensuring structural integrity. The 110-16mm height of the rod 2 provides sufficient geometric space for the bottom contact part 4 and the side positioning groove. The 16-12mm width of the head adapts to the dome / hat-shaped outer contour and the top positioning groove, avoiding structural compression or deformation due to dimensional constraints. This ensures the integrity and performance of each functional structure, achieving synergistic optimization of multiple structures.

[0062] This solution relies on the structural optimization of the dome / hat-shaped head 1 of the bus conductor to achieve a significant reduction in height while maintaining the same current carrying capacity. The core principle follows the logic of improving heat dissipation efficiency, decoupling current carrying capacity and size, and coordinating the adaptation of component size. At the same time, through the size fine-tuning and positioning function adaptation mechanism, a balance between compactness and scalability is achieved. The specific principle is as follows: Traditional T-shaped and strip-shaped conductors rely on increasing height to reduce resistance and control temperature rise to ensure current carrying capacity, resulting in a strong binding between current carrying capacity and conductor height. The heights reach 27mm and 32.2mm respectively under 125A current carrying capacity. In contrast, the dome-shaped and hat-shaped conductors of this solution maximize the effective heat dissipation area through curved surface structure, improve heat dissipation efficiency and heat conduction rate, and can maintain the same current carrying capacity without relying on increasing height. This reduces the height to 22.19mm and 20.72mm respectively under 125A current carrying capacity, achieving a significant reduction in height. As the core component of the busbar trunking, the conductor's height directly determines the fit size of the metal outer shell conductor channel and the insulator housing cavity. Reducing the conductor height allows for simultaneous compression of the height and volume of the outer shell and insulator, reducing material usage from the structural source. Simultaneously, the compact conductor structure leads to a reduction in the overall busbar trunking assembly size, resulting in lower overall weight and reduced energy consumption and operational complexity during handling, transportation, and installation. Furthermore, the conductor width and height support gradient fine-tuning based on load-bearing capacity, and the positioning function can be enhanced in sync with the conductor size. When upgrading to higher current-carrying specifications, only minor adjustments to the conductor size are needed without altering the overall structural form, maintaining component adaptability and achieving a balance between high-specification upgrades and minimal size increments, continuously maintaining compact and lightweight characteristics.

[0063] This solution overcomes the bottleneck of traditional conductors that inevitably increase size to increase current carrying capacity by optimizing conductor height and derivative designs while maintaining current carrying capacity. It offers advantages in structure, cost, operation, and scalability, with the following benefits: First, it achieves an extremely compact structure with significant lightweight advantages at the same current carrying capacity. At a current carrying capacity of 125A, the height of dome-shaped and cap-shaped conductors is reduced by 17.8%, 35.6%, and 23.3%, 35.7% respectively compared to traditional T-shaped and strip-shaped conductors. This height reduction directly leads to a coordinated reduction in the size of the insulator, metal shell, and related components. The overall busbar structure can be miniaturized without sacrificing current carrying capacity, while significantly reducing the amount of component materials used, balancing the stringent space requirements and lightweight goals of high-density power distribution scenarios. Second, it significantly reduces the total lifecycle cost. The reduction in conductor, insulator, and shell materials directly lowers raw material procurement costs; the lightweight structure reduces energy consumption and costs during handling, warehousing, and transportation. Furthermore, installation does not require large equipment, reducing labor and construction costs, thus optimizing the entire cost chain from materials to processing, transportation, and installation. Third, significantly improved ease of operation. The compact and lightweight busbar duct components are easier to handle, position, and install manually, especially suitable for confined power distribution spaces and high-altitude operations, reducing installation difficulty and safety risks; at the same time, it simplifies subsequent operation and maintenance processes, improving work efficiency. Fourth, highly flexible upgrades to meet diverse needs. Conductor width and height can be finely adjusted as needed to match different load-bearing capacities, and the positioning function can be enhanced synchronously with size. When upgrading to higher current-carrying specifications, only minor adjustments to conductor dimensions are required, without the need to reconstruct core components such as the shell and insulator, maintaining structural compactness while reducing the cost and complexity of upgrades and modifications, achieving "one-time architecture - multi-specification adaptation". Fifth, synergistic improvement in component adaptability and structural stability. The optimized conductor height and the synergistic reduction in component size make the fit between the insulator, shell, and conductor more precise, avoiding structural loosening caused by redundant space. At the same time, the positioning function is enhanced with size adaptation, further ensuring conductor posture stability, balancing compactness and operational reliability. Sixth, expanded range of applicable scenarios. The compact and lightweight design, along with the flexible upgrade capabilities, make busbar trunking suitable for various power distribution scenarios, such as data centers, industrial plants, and high-rise buildings. It can meet existing current carrying capacity requirements and also meet the upgrade needs of future load growth, thereby enhancing the long-term applicability and market competitiveness of the product.

[0064] On the other hand, such as Figure 7 As shown, a busbar trunking is also provided, comprising: a metal housing 5, an insulator 8, and a busbar conductor as described above. The metal housing 5 is provided with a conductor groove for mounting the busbar conductor, and the insulator 8 is disposed between the conductor groove and the busbar conductor.

[0065] Based on the above scheme, the conductor groove of the metal shell 5 provides a precise installation reference and structural support for the bus conductor and insulator 8. The dimensional adaptability of the conductor groove limits the installation posture of the insulator 8 and the bus conductor, preventing component misalignment. The insulator 8 fills the space between the conductor groove and the bus conductor, achieving insulation between the conductor and the metal shell 5 to eliminate the risk of leakage. Furthermore, its own positioning protrusions form a concave-convex fit with the bus conductor positioning groove, working in conjunction with the conductor groove to strengthen the three-dimensional constraint on the bus conductor, precisely controlling the conductor's axial, radial, and circumferential degrees of freedom, ensuring conductor posture stability. The non-uniform structure of the bus conductor forms an efficient fit with the conductor groove and insulator. The heat dissipation structure of the head 1 can form multiple heat dissipation pathways through the insulator and the metal shell, allowing heat to be conducted from the conductor head 1 and the rod 2 to the insulator. The heat is quickly dissipated from the conductor through the metal casing, while the closed nature of the conductor slot optimizes heat convection efficiency and prevents heat accumulation. In terms of electrical safety, the metal casing provides physical protection and electromagnetic shielding. Combined with the insulation performance of the insulator and the optimized electric field structure of the conductor, it avoids the risks of electric field concentration and insulation breakdown. For conductive connections, the precise fit between the bottom contact part 4 of the busbar conductor rod 2 and the plug-in box's claws, relying on the positioning constraints of the insulator and conductor slot, ensures stable electrical contact posture. Current is transferred from the conductor through the contact part 4 to the plug-in box and then distributed to the load, achieving efficient conductivity. In the face of extreme conditions such as short circuits, the metal casing provides rigid support for internal components, resisting structural deformation caused by short-circuit electromagnetic forces. Combined with the anti-deformation design of the busbar conductor and the buffering effect of the insulator, it maintains the overall structural integrity and prevents the escalation of faults.

[0066] Furthermore, a second positioning part is provided on the inner side of the insulator 8 to cooperate with and position the first positioning part 3. The second positioning part and the first positioning part 3 are designed to be exclusively matched one-to-one. Its geometry, size, and extension trajectory are completely matched with the first positioning part 3. During assembly, a precise concave-convex fit can be formed, applying reverse constraint to the conductor from the insulator side. This forms a bidirectional interlock with the positive limiting of the first positioning part 3 on the conductor side, completely eliminating the redundant degrees of freedom of the conductor in the axial, radial, and circumferential directions within the insulator, and precisely limiting the relative position and orientation of the two. This concave-convex fit structure has natural assembly guidance. During assembly, the second positioning part can guide the first positioning part 3 to smoothly fit along a preset trajectory, automatically correcting slight alignment deviations of the conductor and avoiding manual precision alignment. The concave-convex structure after fitting ensures that the contact between the conductor and the insulator is only... Occurring at the positioning mating surface, the contact area and contact surface are precisely controlled. Under the assembly force, a high-pressure and tight fit can be achieved on the mating surface, while reducing ineffective contact in non-mating areas. The bidirectional interlocking tight fit can maximize the compression of the assembly gap between the conductor and the insulator, significantly reduce the formation of air cavities in the gap, reduce thermal resistance, and allow the heat generated by the conductor to be quickly conducted to the insulator through the mating surface. In addition, the concave-convex interlocking structure can improve the bonding stiffness between the conductor and the insulator, resist the impact of external factors such as transportation, vibration, and short-circuit electromagnetic forces, prevent relative displacement between the conductor and the insulator, always maintain the preset posture of the conductor, and ensure the precise docking of the conductor contact part 4 with the plug-in box claw.

[0067] Meanwhile, connectors 6 are respectively provided on both sides of the end of the metal shell 5, which are connected to the end cap 7. The metal shell 5 is provided with a slot 51 for the connectors 6 to be installed. The opposite sides of the two connectors 6 are respectively provided with abutment portions 61, which abut against a portion of the groove side of the slot 51 to form a limit. In this structure, the integrally formed slot 51 provides a standardized installation benchmark and radial constraint for the connectors 6, which can accurately limit the pre-installation position of the connectors 6, ensure the coaxiality and positional consistency of the installation of the left and right sets of connectors 6, and provide a stable positioning basis for the precise docking of the end cap 7 and the metal shell 5. The rigid abutment portions 61 protruding on the opposite sides of the connectors 6 abut against the inner groove side of the slot 51 can directly offset the radial extrusion force generated when the connectors 6 are tightened, and block the extrusion force from being transmitted to the conductor mounting cavity inside the metal shell 5. This avoids the problem of deformation of the shell groove and shrinkage of the inner diameter of the conductor mounting cavity caused by excessive extrusion force from the structural source.

[0068] Based on the above working principle, this structure has multiple significant benefits: it greatly improves the assembly accuracy and structural stability of the busbar trunking end connections. The standardized slot 51 and the double limiting constraint of the abutment part 61 ensure the coaxiality and sealing of the connection between the connector 6, end cover 7 and metal shell 5, enhance the vibration and impact resistance of the end structure, effectively avoid the risk of loosening of the end connections and sealing failure during long-term operation of the busbar trunking, and improve the overall reliability of the busbar trunking operation. At the same time, it ensures the dimensional accuracy and positional stability of the conductor installation cavity inside the metal shell 5 from the structural source. The rigid stop and force offset of the abutment part 61 can completely avoid excessive compression of the shell during the installation of the connector 6, eliminate the problem of shrinkage and deformation of the conductor installation cavity and the insulator 8 receiving cavity caused by shell deformation, ensure the preset reasonable fit gap between the insulator 8 and the busbar conductor, effectively control the contact friction resistance during the assembly of the busbar conductor, ensure the smoothness of pushing long-size busbar conductors into the assembly, and greatly reduce the length of long-size conductors. This design reduces assembly difficulty and on-site operation costs, while providing a stable and consistent dimensional basis for the automated assembly of busbar trunking. Furthermore, the structure enhances the assembly protection of insulating and conductive components, avoiding assembly defects such as localized pressure damage to the insulator 8 and decreased insulation performance caused by excessive extrusion of the shell. It also avoids conductor assembly misalignment and insufficient docking accuracy caused by cavity deformation, reducing component damage during assembly and ensuring the electrical insulation safety and conductive connection stability of the busbar trunking during long-term operation. Ultimately, this structure significantly improves the assembly consistency and mass production economy of busbar trunking. The integrated slot 51 and standardized connector 6 with abutment part 61 allow for precise control of the connector 6's installation stroke, eliminating shell deformation differences caused by uneven pressing of the connector 6 during manual assembly. This ensures the consistency of assembly dimensions within the same batch of products, reduces the defect rate during mass production, simplifies post-assembly debugging procedures, effectively improves production efficiency, and reduces manufacturing and maintenance costs throughout the product's lifecycle.

[0069] Furthermore, the entire surface of the busbar conductor is covered by the metal casing 5. Except for the bottom surface used for PIN connections, there are no other air gaps in direct contact with the busbar conductor. This allows over 90% of the busbar conductor's surface area to effectively transfer heat to the metal casing 5, thus helping to reduce the operating temperature of the busbar conductor. Moreover, by optimizing the thickness of the metal casing 5, both its strength and heat dissipation are improved. The top surface of the metal casing 5 also features a heat dissipation fin design, increasing the heat dissipation area by 20%.

[0070] On the other hand, a power device is also provided, including: a plug-in box, a connector, and multiple busbar troughs as described above. Each pair of busbar troughs is connected via the connector, and the plug-in box is electrically connected to the busbar conductor via prongs. Multiple busbar troughs are connected segment by segment via the connector. The connector achieves both mechanical fastening and precise positioning of the metal shells and conductors of adjacent busbar troughs, and completes electrical conduction, eliminating contact gaps and conductive obstructions at the splicing points, forming a continuous long-distance power distribution link. It also adapts to the compact structure of the busbar troughs, ensuring uniform overall dimensions and consistent structural rigidity after splicing. The plug-in box forms a precise electrical connection with the bottom contact portion 4 of the busbar conductor via prongs. Relying on the concave-convex positioning structure of the busbar conductor and insulator, and the optimized shape of the contact portion 4, the prongs can smoothly embed and be precisely constrained, avoiding contact offset and ensuring effective contact area and stable contact pressure during power extraction. In the power distribution link, current flows through the busbar... The busbar trunking conducts power through connectors, enabling continuous transmission across the trunking. The plug-in box draws power from the conductor via its pins and distributes it to the load, such as a server, forming a complete conductive path. During operation, all components work together to resist external interference: the connectors provide rigid support and conductive stability at the joints, resisting loosening caused by short-circuit electromagnetic forces and vibrations; the conductor and insulator positioning system constrains the conductor's posture, ensuring stable contact between the pins and the conductor; the busbar trunking's own heat dissipation system is adapted to the overall structure of the device, accelerating heat dissipation throughout the entire process; simultaneously, the physical protection of the metal casing, electromagnetic shielding, and the insulating barrier of the insulator form multiple layers of safety protection, mitigating risks such as leakage and electromagnetic interference.

[0071] Furthermore, a contact portion 4 is provided on the bottom side of the rod 2, and a conductive portion is provided on the top side of the claw that contacts the contact portion 4. The specific shape of the conductive portion needs to be adaptively adjusted according to the shape of the contact portion 4. The conductive portion on the top side of the claw is not a fixed shape, but is specifically and adaptively designed according to the geometry of the contact portion 4 on the bottom side of the rod 2, so that the contour of the conductive portion and the contact portion 4 are completely mutually fitted, forcing a tight surface contact, replacing the point / line contact that may occur with the traditional fixed-shape conductive portion. The adaptive shape design can compensate for minor dimensional deviations and assembly misalignment deviations of the conductor, claw, and insulator. Even with slight manufacturing or assembly errors, the conductive portion can still maintain a full fit with the contact portion 4 through contour adaptation, maintaining uniform contact pressure. Combined with the positioning system of the conductor and insulator, the adaptive fit between the conductive portion and the contact portion 4 can be further improved. The step-constraint design maintains the relative orientation of the insert and conductor to prevent contact misalignment and ensure a stable current conduction path. During current conduction, the surface contact shape ensures that the current density is evenly distributed along the contact interface, avoiding Joule heating surges caused by localized current concentrations. Simultaneously, the tight surface contact significantly reduces the thermal resistance of the contact interface, allowing the heat generated in the contact area to be quickly conducted through the insert to the conductive part, then through the bus conductor, and finally dissipated through the top side of the metal casing, forming an efficient heat transfer path. In the face of external impacts such as vibration and short-circuit electromagnetic forces, the adaptive shape and tight fit enhance the interlocking of the contact interface, resist relative displacement, and maintain a stable contact state.

[0072] In the description herein, it should be understood that the terms "upper," "lower," "left," "right," and other orientations or positional relationships are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used merely for descriptive distinction and have no special meaning.

[0073] In the description of this specification, references to terms such as "an embodiment," "example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example.

[0074] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style of the specification is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

[0075] The technical principles of this application have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of this application and should not be construed as limiting the scope of protection of this application in any way. Based on this explanation, those skilled in the art can readily conceive of other specific embodiments of this application without inventive effort, and these embodiments will all fall within the scope of protection of this application.

Claims

1. A busbar conductor, characterized in that, include: The head (1) and the rod (2) are integrally formed. The width of the head (1) is greater than the width of the rod (2), and at least the side of the head (1) away from the rod (2) has a smooth arc transition. The rod (2) is also provided with a first positioning part (3).

2. The bus conductor according to claim 1, characterized in that, The side of the rod (2) is flat.

3. The bus conductor according to claim 1, characterized in that, The outer contour of the head (1) is dome-shaped, and the connection position with the rod (2) is an arc transition.

4. The bus conductor according to claim 1, characterized in that, The outer contour of the head (1) is hat-shaped, with an arc-shaped top side and two sides extending vertically. The bottom end of the side extends horizontally toward the rod (1) and connects to the side of the rod (1).

5. The busbar conductor according to any one of claims 1-4, characterized in that, The first positioning part (3) is a positioning groove provided on the side of the rod (2), and the positioning groove extends along the length direction of the rod (2).

6. The bus conductor according to claim 5, characterized in that, The positioning groove is V-shaped and recessed on the side of the rod (2).

7. The bus conductor according to any one of claims 1-4, characterized in that, The head (1) is provided with the first positioning part (3), which is a positioning groove located at the top of the head (1) and extends along the length direction of the head (1).

8. The bus conductor according to any one of claims 1-4, characterized in that, The bottom side of the rod (2) is provided with a contact part (4) that can make contact with the plug claw of the plug box and conduct electricity.

9. The bus conductor according to claim 8, characterized in that, The contact portion (4) includes two inclined sides that slope downwards from the outside to the inside, and the bottom ends of the two inclined sides intersect. Alternatively, the contact portion (4) includes two inclined edges that slope upwards from the outside to the inside, and a circular groove (41) connecting the top of the two inclined edges.

10. The bus conductor according to any one of claims 1-4, characterized in that, The head (1) has a width of 6-12 mm, the rod (2) has a width of 3-6 mm, the head (1) has a height of 8-12 mm, and the rod (2) has a height of 10-16 mm.

11. A busbar trunking system, characterized in that, include: The metal casing (5), the insulator (8), and the bus conductor as described in any one of claims 1-10, wherein the metal casing (5) is provided with a conductor groove for mounting the bus conductor, the insulator (8) is disposed between the conductor groove and the bus conductor, and the inner side of the insulator (8) is provided with a second positioning part that cooperates with the first positioning part (3) for positioning. The metal shell (5) has connectors (6) on both sides of its end, which are connected to the end cap (7). The metal shell (5) has a slot (51) for the connectors (6) to be installed. The two connectors (6) have abutting parts (61) protruding on opposite sides. The abutting parts (61) abut against a portion of the slot side of the slot (51) to form a limit.

12. An electric power device, characterized in that, include: The assembly includes a plug box, a connector, and a plurality of busbars as described in claim 11, with each pair of busbars connected by the connector, and the plug box electrically connected to the busbar conductor via a pin.

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