Bus Bar Cavity Connection for Screwless Joining and Heat Dissipation
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Solution Overview
Problem
Conventional bus bar connection methods require a large number of screws and an additional electric field shielding, especially when connecting non-flat bus bars, which increases complexity and reduces efficiency due to the need for flattening ends and causing uneven electric fields.
Innovation Solution
A bus bar system with a cavity connection portion that eliminates the need for screws and electric field shielding by using a component within the cavity to couple bus bars, allowing for face-to-face contact and improved heat dissipation through fluid convection, while also enabling flexible connections and uniform electric field distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screw connection method is used to connect bus bars, then the connection is reliable, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple connection functions into a single integrated connection component. This component includes a connection body with first and second connection portions that can simultaneously connect multiple bus bars, eliminating the need for separate screws and nuts for each connection point. The connection component integrates the fastening, positioning, and electrical connection functions into one piece, thereby reducing the total number of parts while maintaining reliable connections.
2Ease of manufacture
If bus bar ends are flattened to enable screw connection, then the connection is possible, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
Instead of modifying the bus bar ends to fit conventional connection methods (flattening), the invention inverts the approach by designing a connection component that adapts to the original bus bar end shapes. The connection component includes adapted connection portions that match various bus bar end configurations, eliminating the need for preprocessing the bus bars while maintaining secure connections.
3Strength
If screws are used to connect bus bars, then the connection is secure, but uneven electric field is generated near the bus bar ends
Solution Approach 1:
The connection component is designed with non-uniform structural characteristics at different locations to address local requirements. The first and second connection portions have different geometries optimized for their respective connection needs, and the connection body includes features that locally compensate for electric field disturbances. This localized structural optimization maintains connection strength while minimizing electric field inhomogeneity.
4Object-generated harmful factors
If additional electric field shielding is added to avoid inhomogeneities, then the electric field uniformity is improved, but the device complexity and number of parts increase
Solution Approach 1:
The connection component is designed to perform multiple functions simultaneously: mechanical fastening, electrical connection, positioning, and electric field management. The integrated structure includes features that address electric field uniformity without requiring separate shielding components, thereby achieving electric field control as part of the primary connection function rather than as an additional measure.
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
This solution reduces the number of parts and assembly time, enhances heat dissipation, and improves insulating performance by eliminating the need for additional shielding and flattening processes, resulting in a more efficient and reliable bus bar connection.
Implementation Method 1
the hollow cavity of the connection portion allows convection of the fluid within the cavity, thereby improving the heat dissipation performance of the bus bar system
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
The present disclosure relates to a bus bar system and an apparatus for bus bar connection. The bus bar system comprises: a plurality of members; a component configured to couple the plurality of members to form a connection portion comprising a cavity, and the component is arranged in the cavity. By employing the bus bar system and the apparatus for bus bar connection according to the present disclosure, it is possible to achieve a significant reduction in the number of parts for bus bar connection without requiring a large number of screws or electric field shieldings, eliminating the process of flattening both ends of the bus bars, improving the heat dissipation performance, improving the working efficiency thanks to simple, fast and reliable bus bar connection.