Bus Bar Contact Surface Structure for Lower Connection Resistance
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Solution Overview
Problem
Existing electronic components with bus bars experience high electrical connection resistance and current loss due to large contact surface resistance, leading to heat generation and deformation.
Innovation Solution
The bus bar features a hole with an unevenness structure around the opening, allowing it to bite into and pressure-contact with a contacting member, increasing the contact area and reducing resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a flat contact surface is used for the bus bar, then the manufacturing process is simple, but the electrical connection resistance is large causing current loss and heat generation
Solution Approach 1:
The bus bar contact surface features localized unevenness structures (protrusions and recesses) around the hole opening, while other areas remain relatively simple. This local modification increases the contact area and reduces electrical resistance without requiring complete structural complexity throughout the entire bus bar, thus reducing current loss while maintaining manufacturing feasibility.
Solution Approach 2:
The unevenness structure includes protrusions with curved surfaces rather than sharp edges, and recesses with rounded bottoms. These curved geometries increase the actual contact area with the contacting member compared to flat surfaces, improving electrical connection and reducing resistance-induced current loss while being manufacturable through standard forming processes.
2Reliability
If the contact area between bus bar and contacting member is increased, then electrical connection resistance is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The unevenness structure is formed as an integrated feature of the bus bar during the hole formation process itself, rather than as a separate subsequent operation. The protrusions and recesses are pre-formed around the hole opening in the same manufacturing step, ensuring consistent positioning and reducing the need for additional high-precision operations that would increase manufacturing complexity.
Solution Approach 2:
The unevenness structure consists of protrusions and recesses that are nested around the hole opening, with the recesses positioned within the hole's periphery and protrusions extending outward. This nested arrangement maximizes contact area within the limited space around the hole while maintaining a compact geometry that does not require excessive manufacturing precision beyond standard capabilities.
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 unevenness structure enhances electrical connection by increasing contact area and preventing current loss, ensuring stable electrical conductivity.
Implementation Method 1
an unevenness region having an unevenness structure is formed around the hole in a contact surface where the hole opens... the unevenness structure can bite into a contacting member being in contact with the bus bar
Data Source
AI summary
An electronic component includes a main body and a bus bar. The main body includes an electronic element. The bus bar is electrically connected to the electronic element. The bus bar includes a hole. The hole opens at a contact surface. An unevenness region is formed at the contact surface. The unevenness region has an unevenness structure around the hole.