Epoxy-Coated Bus Bars With Localized Heat Contact Exposure
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Solution Overview
Problem
Existing methods for creating clean conductor areas on epoxy-coated bus bars are labor-intensive, costly, and destructive, particularly when attempting to expose conductive joints for electrical connections, as they often require masking, specialized tapes, or extensive rework processes like heating and manual stripping.
Innovation Solution
A method involving localized heat application to transition the epoxy from a glassy to a rubbery state, allowing for automated cutting and removal of the coating without damaging the conductor surface, using induction or infrared heaters and controlled cutting tools, and then cooling to restore the epoxy to a glassy state for safe handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If masking and demasking approach is used to create clean conductor areas, then conductive joints can be protected from epoxy, but the process becomes labor intensive and requires costly specialized tapes
Solution Approach 1:
The patent applies preliminary action by creating a protective barrier (such as a release layer or protective coating) on the conductive joint areas before the epoxy coating is applied. This prevents epoxy adherence to areas that should remain conductive, eliminating the need for post-application masking and demasking operations.
Solution Approach 2:
The patent extracts the protective function from the masking process by incorporating it directly into the bus bar structure through a release layer or protective coating applied beforehand. This separates the protection function from the epoxy coating process itself, allowing epoxy to be applied freely without subsequent removal operations.
2Ease of repair
If heat is applied to strip epoxy coating for rework, then defective coating can be removed, but the process is time-consuming and has limitations on oven size and energy usage
Solution Approach 1:
The patent applies parameter changes by carefully controlling the heating temperature to reach the glass transition temperature of the epoxy, transforming it from a glassy state to a rubbery state. This controlled parameter change allows for easy removal of the epoxy coating without requiring extensive heating or prolonged processing times.
Solution Approach 2:
The patent utilizes phase transitions by heating the epoxy coating to its glass transition temperature, causing it to transition from a rigid glassy state to a flexible rubbery state. This phase change makes the epoxy coating removable without requiring high-temperature stripping or extensive manual labor.
3Manufacturing precision
If localized heat is applied to transition epoxy from glassy to rubbery state for automated cutting, then clean conductor areas can be created with minimal surface damage, but the process requires precise temperature monitoring
Solution Approach 1:
The patent applies feedback by implementing temperature monitoring and control systems that continuously measure the temperature during localized heating and adjust the heat input accordingly. This ensures the epoxy reaches the glass transition temperature without overheating, maintaining manufacturing precision while managing the measurement complexity.
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 method efficiently and cost-effectively creates clean conductor areas on epoxy-coated bus bars with minimal surface damage, enabling automated and precise exposure of electrical contact points, thus simplifying the manufacturing process and reducing energy and time consumption.
Implementation Method 1
one can safely and economically, preferably via automated apparatus, put the epoxy into its rubbery state by positioning the bar and applying localized heat at a select area of the coating; monitoring the heating to above the glass transition temperature of the epoxy
Implementation Method 2
the application of heat may be done through one of induction or infrared heaters
Implementation Method 3
the application of heat may be done through one of induction or infrared heaters
Implementation Method 4
bringing cutting tools into contact with a subject area of the epoxy for cutting and removing the rubbery coating away from the bus bar
Implementation Method 5
cooling the bus bar to bring adjacent coating back to the glassy state
Data Source
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AI summary
An automated process for producing exposed electrical contact areas on the conductor part of an epoxy coated bus bar. When the epoxy coating is in the glassy state, one can safely and economically, preferably via automated apparatus, put the epoxy into the rubbery state by positioning the bar and applying localized heat at a select area of the coating; monitoring the heating to above the glass transition temperature of the epoxy, bringing cutting tools into contact with the epoxy for cutting and removing the rubbery coating away from the bus bar, and cooling the bus bar to bring adjacent coating back to the glassy state, thereby leaving an exposed electrical contact area of conductor on the bus bar with little or no surface damage.