Plated Contact Insert Bus Bar Assembly for Lower-Cost Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bus bar assembly manufacturing processes are costly due to the need for specialized tooling and additional processing steps required for selectively plating the contact portion, or the requirement for more expensive tin or silver-plating materials when plating the entire bus bar.
Innovation Solution
A bus bar assembly is designed with a contact insert made of a harder electrically conductive material, where the insert has a plated surface and is mechanically and electrically connected to the bus bar, reducing the need for extensive plating of the entire bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If selective plating of the contact portion is performed, then plating material cost is reduced, but manufacturing complexity increases due to specialized tooling and additional processing steps
Solution Approach 1:
The bus bar is divided into two functional components: an unplated body portion and a separately plated contact insert. This segmentation allows the expensive plating material to be applied only to the contact insert where electrical connection is needed, while the bus bar body remains unplated, thus reducing overall plating material consumption without requiring complex selective plating tooling.
Solution Approach 2:
The contact portion is extracted as a separate insert component that can be plated independently using standard plating processes. This extracted contact insert is then installed into the bus bar body, eliminating the need for specialized selective plating equipment and reducing manufacturing complexity while maintaining cost-effective plating material usage.
2Reliability
If the entire bus bar is plated, then electrical conductivity at the contact surface is ensured, but material cost increases due to higher consumption of expensive tin or silver plating materials
Solution Approach 1:
The contact insert is provided with a plated surface specifically at the contact area where electrical connection is required. This local quality approach ensures high electrical conductivity and reliability at the critical contact surface while avoiding unnecessary plating of the entire bus bar, thereby significantly reducing expensive plating material consumption.
3Quantity of substance
If a contact insert is used, then plating material cost is reduced, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The contact insert is integrated into the bus bar assembly through mechanical engagement features such as interference fits, keyways, or welding. This merging of the insert with the bus bar body creates a unified structural unit that maintains electrical continuity and mechanical stability, thereby reducing device complexity despite the additional component.
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 production costs by minimizing the use of expensive plating materials and simplifying the manufacturing process, while maintaining effective electrical conductivity and mechanical stability.
Implementation Method 1
The resistance of an electrical connection to an electrical bus bar is reduced and stabilized by plating an electrically conductive material, such as tin or silver, on the contact portion of the bus bar
Implementation Method 2
The collar is in an interference fit with an inner wall of the first bore such that a portion of the bus bar is deformed and disposed within the annular groove
Implementation Method 3
a portion of the bus bar is deformed and disposed within the annular groove
Data Source
AI summary
A bus bar assembly includes a bus bar formed of a first electrically conductive material having a planar contact portion. The bus bar defines a first bore extending through the contact portion. The bus bar assembly further includes a contact insert formed of a second electrically conductive material that has a greater hardness than the first electrically conductive material. The contact insert defines a first surface that is mechanically and electrically connected to the contact portion of the bus bar. The contact insert defines a second surface this is plated with a third electrically conductive material which is different than the second electrically conductive material. The contact insert defines a smooth second bore coaxial with the first bore and extending from the first surface to the second surface.