Bus-Bar Assembly with Vertical Stacking to Reduce Power Loop Length
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Solution Overview
Problem
Conventional bus-bar assemblies in HVAC systems have lengthy power loops, which reduce thermal dissipation efficiency and increase the size of the PCB board, leading to cumbersome packaging and potential electrical leakage.
Innovation Solution
A bus-bar assembly design with a first and second bus-bar, where the second bus-bar is spaced apart and superposed to the first, with connecting legs on a single side to reduce the power loop length and enhance thermal dissipation efficiency, while avoiding electrical leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connecting legs are provided on both sides of the bus-bar assembly, then the electrical connection is more stable, but the power loop length increases reducing thermal efficiency
Solution Approach 1:
The patent transitions from a planar arrangement where connecting legs are distributed on both sides of the bus-bar to a three-dimensional configuration where the second bus-bar is positioned above the first bus-bar with connecting legs on the same side. This vertical stacking reduces the power loop length while maintaining electrical connection stability through the layered bus-bar structure.
2Reliability
If the second bus-bar is laterally spaced from the first bus-bar, then electrical insulation is provided, but the power loop length increases
Solution Approach 1:
The patent resolves this contradiction by moving the insulation approach from the lateral dimension to the vertical dimension. The second bus-bar is positioned above the first bus-bar with insulation provided in the vertical direction, allowing the connecting legs to be arranged on the same side without increasing power loop length.
3Length of moving object
If connecting legs are arranged on one side only, then the power loop length is reduced, but electrical insulation between bus-bars becomes critical
Solution Approach 1:
The patent addresses the electrical leakage risk by introducing vertical separation between the first and second bus-bars. The insulation is provided in the vertical dimension through the housing structure, allowing connecting legs to be positioned on the same side without compromising electrical isolation between the bus-bars.
4Reliability
If the PCB board size is increased to accommodate bus-bar connections, then connection reliability is improved, but packaging becomes cumbersome
Solution Approach 1:
The patent reduces the PCB board size by transitioning from a horizontal expansion approach to a vertical stacking approach. The first and second bus-bars are arranged vertically with connecting legs on the same side, allowing compact PCB layout and improving packaging efficiency while maintaining connection reliability.
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 redesigned bus-bar assembly reduces power loop length, enhancing thermal efficiency and allowing for a smaller PCB size, while preventing electrical leakage and improving packaging efficiency.
Implementation Method 1
The heating elements are electrical heating elements powered by an electrical source
Data Source
AI summary
A heater device for a vehicle is described. The heater device include a plurality of heating elements, a printed circuit board, a first bus-bar, and a second bus-bar. The first bus-bar having a first set of connecting legs is formed in a first side of the first bus-bar. The first set of connecting legs is adapted to be connected with a first set of heating elements amongst the plurality of heating elements. The second bus-bar having a coupling element is formed in a first side of the second bus-bar to couple with a first side of the PCB. Further, a second set of connecting legs is formed adjacent to the coupling element and adapted to be coupled to the first side of the PCB. The second set of connecting legs is adapted to connect with a second set of heating elements amongst the plurality of heating elements.