Aligned Busbar Assembly Insulation Mounting
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Solution Overview
Problem
Conventional busbar assemblies in power distribution systems face issues with reduced current-carrying capacity due to misaligned through-holes and high mold costs associated with segmented injection molded insulating members, which complicate assembly and increase costs.
Innovation Solution
A busbar assembly design featuring aligned through holes in the busbars and insulating member, along with a simplified insulation mounting assembly and fastener system, eliminates the need for misaligned holes, enhancing current-carrying capacity and reducing mold costs by using a single-piece insulating member and paired sub-mounting members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple misaligned through-holes are provided in busbars to secure insulating member, then the insulating member can be mounted and secured, but the effective current carrying cross-sectional area of the busbar decreases
Solution Approach 1:
The patent merges multiple misaligned through-holes into a single aligned through-hole that passes through both busbars and the insulating member together. This consolidation reduces the total number of holes from multiple to one, thereby preserving the effective current carrying cross-sectional area while still achieving secure mounting of the insulating member between the busbars.
2Reliability
If segmented injection molded member is used for intermediate insulating member, then electrical isolation is achieved, but mold cost increases and assembly difficulty increases
Solution Approach 1:
The patent combines multiple segmented insulating members into a single integrated intermediate insulating member that provides electrical isolation between the busbars. This single-piece design eliminates the need for complex multi-step assembly procedures required for segmented members, while maintaining the essential electrical isolation function.
Solution Approach 2:
The insulating member is designed with integrated features including recesses and protrusions that segment the functional zones within a single piece, allowing different regions to serve different purposes (mounting, isolation, alignment) without requiring separate components.
3Reliability
If segmented injection molded member is used for intermediate insulating member, then electrical isolation is achieved, but mold cost increases
Solution Approach 1:
The patent consolidates multiple segmented insulating members into a single intermediate insulating member that can be manufactured using a single mold. This eliminates the need for multiple expensive molds required for producing segmented members, while maintaining the electrical isolation function through the integrated design.
Data Source
AI summary
A busbar assembly includes a first and a second busbar, an intermediate insulating member, an insulation mounting assembly, and a fastener. The busbars are arranged at an interval in a thickness direction of the busbar assembly. First and second through holes are formed in respective ones of the busbars. The intermediate insulating member is arranged between the first busbar and the second busbar. A third through hole is formed in the intermediate insulating member and is aligned with the corresponding through holes in the thickness direction. At least a portion of the insulation mounting assembly is inserted through the aligned first, second, and third through holes to fix the first busbar and the second busbar relative to the intermediate insulating member. The fastener is mounted at least partially within the insulation mounting assembly to fix the insulation mounting assembly, the intermediate insulating member, the first and second busbars.