Three-Dimensional Wire Connectors for Complex Power Routing
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Solution Overview
Problem
Existing solutions for connecting electrical components to a power supply, such as busbars and contact boards, are limited in their ability to form complex three-dimensional line paths, as they can only be deformed or angled to a certain extent, restricting their adaptability in complex arrangements.
Innovation Solution
A device comprising at least one three-dimensionally shaped wire with contact areas at its ends and other points, allowing for complex three-dimensional line paths, with a round cross-section for optimal deformability, and featuring flat embossments or holes for secure connections, enabling the formation of very complex shapes for connecting electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If busbars are made from punched and bent sheets, then manufacturing is relatively simple, but the ability to form complex three-dimensional line paths is limited
Solution Approach 1:
The patent changes the fundamental geometric parameter of the conductor from flat sheet form to round wire form. This parameter change enables the conductor to be bent into complex three-dimensional paths while maintaining manufacturing feasibility through standard wire forming processes
Solution Approach 2:
The patent employs curved and three-dimensional wire paths instead of flat bent sheets. The round cross-section of the wire allows it to be formed into complex curved paths in three-dimensional space, achieving the desired adaptability while remaining manufacturable
2Reliability
If contact areas are formed as flat embossments on the wire, then secure contact connections are achieved, but the contact area size is limited
Solution Approach 1:
The patent places additional contact surfaces within the三维 space created by the wire's curved path. Multiple contact areas can be positioned at different locations along the wire, effectively nesting multiple connection points within the overall wire structure, thereby increasing total contact area while maintaining compact form
Solution Approach 2:
The patent transitions from two-dimensional flat contact areas to three-dimensional contact surfaces distributed along the curved wire path. This dimensional change allows contact areas to be positioned in multiple spatial locations, increasing the effective contact area available for connections
Data Source
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AI summary
The invention relates to a device (30) for connecting electrical components (20, 22) with a power supply (42). The invention is characterised in that the device (30) is formed by a three-dimensionally bent wire (32), in which contact regions (36) are formed at least at the ends thereof, and preferably also between same. In comparison to known devices that generate a connection with power rails or via contact plates, the device according to the invention is substantially easier and more cost-effective to produce and can be three-dimensionally deformed virtually as desired.