Bendable Shielded Bus Bar With Foil Wrapping
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Solution Overview
Problem
Existing bus bars with braided shielding layers suffer from performance degradation when subjected to extreme twists and bends, leading to separation of the braiding and potential RF signal leakage.
Innovation Solution
A bus bar assembly featuring a conductive foil shielding layer with embossed patterns, wrapped around an insulating layer, allowing for bending and twisting without separation gaps, using a conductive foil wrap with overlapping sections to maintain shielding integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a braided shielding layer is used on the bus bar, then the shielding effectiveness is improved, but the shielding performance degrades when the bus bar is bent or twisted
Solution Approach 1:
The patent replaces the braided shielding layer with a continuous foil shielding layer that can flex and deform without breaking. The foil is wrapped around the bus bar and secured with adhesive tape, creating a continuous protective layer that maintains shielding integrity even when the bus bar is bent or twisted, unlike the braided structure that separates under deformation.
Solution Approach 2:
The shielding structure combines multiple materials with complementary properties: a conductive foil for electromagnetic shielding, adhesive tape for secure attachment and flexibility, and heat shrink tubing for additional protection. This composite approach creates a shielding system that is both effective and resilient to mechanical deformation.
2Adaptability or versatility
If the bus bar is bent or twisted to make electrical connections, then the adaptability is improved, but the braided shielding separates and RF signals leak
Solution Approach 1:
The continuous foil shielding layer can flex and deform with the bus bar during bending and twisting operations, maintaining its protective function throughout the deformation process. The foil's continuous structure prevents RF signal leakage even when the bus bar is configured for various electrical connections.
Solution Approach 2:
The shielding layer is applied to the bus bar before the bus bar is installed or bent into its final configuration. This preliminary application ensures that the shielding is already in place and will move with the bus bar during subsequent installation and deformation, preventing separation and maintaining shielding effectiveness.
3Stability of the object's composition
If a continuous foil shielding layer is used instead of braided shielding, then the shielding maintains integrity during bending, but the ease of manufacture may be affected
Solution Approach 1:
The foil shielding layer is designed to be flexible and conformable, allowing it to be easily wrapped around the bus bar in various configurations. The foil can be cut to size and wrapped manually or with simple equipment, making the manufacturing process straightforward while achieving superior shielding integrity compared to braided alternatives.
Solution Approach 2:
Adhesive tape serves as an intermediary that secures the foil shielding layer to the bus bar without requiring complex fastening mechanisms. The tape simplifies the manufacturing process by providing an easy method to attach the foil continuously along the bus bar, maintaining both ease of manufacture and shielding integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the bus bar to be bent and twisted without degrading the shielding performance, preventing RF signal leakage and maintaining effective electromagnetic shielding.
Implementation Method 1
Electromagnetic shielding acts to reduce the electromagnetic field in a space by blocking the field with barriers made of conductive or magnetic materials. Shielding is typically applied to enclosures to isolate electrical devices from the 'outside world'
Implementation Method 2
Copper is an excellent material for RF shielding because copper absorbs radio and magnetic waves, has a high electrical conductivity, is ductile, malleable, and solders easily
Data Source
AI summary
A bus bar assembly is provided that includes an electrical conductor with a rectangular cross-section. A first insulation layer surrounds the electrical conductor. A shielding layer surrounds the first insulation layer. The shielding layer is formed from an embossed conductive foil wrapped around the first insulation layer with overlapping sections. A method of making the bus bar assembly is provided that includes an electrical conductor being surrounded with a first insulating layer. The first insulating layer is then wrapped with a shielding layer formed from a conductive foil wrapped around the first insulation layer.