Bus Bar Insulator With Offset Mounting Openings
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Solution Overview
Problem
Current supporting insulators for bus bars in conductive enclosures often interfere with the spacing between conductors of opposite polarity and require additional mechanical restraints to prevent axial movement, limiting their geometry and efficiency.
Innovation Solution
A contoured mounting member with offset mounting openings that interleave with adjacent insulators, allowing for close placement while maintaining required spacing and restricting axial motion through bus bar engagement members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional insulators with central mounting openings are used, then the insulator structure is simple, but the distance between adjacent insulators increases and electrical isolation spacing is compromised
Solution Approach 1:
The patent applies asymmetry by offsetting the mounting openings from the geometric centerline of the bus bar holding opening. This asymmetric arrangement allows mounting hardware to be positioned away from the center, enabling adjacent insulators to be placed closer together while maintaining proper electrical isolation spacing between conductors of opposite polarity.
Solution Approach 2:
The patent moves the mounting openings from a central position to an offset position in the transverse direction. This dimensional repositioning allows the mounting hardware to interleave with adjacent insulators, reducing the overall distance between insulators while maintaining required spacing for electrical isolation.
2Device complexity
If conventional insulators without axial restraint features are used, then the insulator geometry is simplified, but additional mechanical restraints are required to prevent axial bus bar movement
Solution Approach 1:
The patent merges the functions of electrical insulation, mechanical mounting, and axial restraint into a single integrated insulator structure. The bus bar engagement members are incorporated directly into the insulator body, eliminating the need for separate mechanical restraints and improving assembly efficiency.
Solution Approach 2:
The insulator structure performs multiple functions simultaneously: it provides electrical insulation between the bus bar and enclosure, provides mounting surfaces for securing the bus bar, and prevents axial movement of the bus bar through engagement members. This multi-functionality reduces the need for additional components.
3Ease of operation
If insulator flanges with central mounting openings are used, then the mounting hardware installation is simplified, but the flanges interfere with close placement of adjacent insulators
Solution Approach 1:
The mounting openings are positioned asymmetrically relative to the bus bar holding opening, allowing the mounting hardware to be offset from the center. This asymmetric configuration reduces the space occupied by flanges and mounting hardware, enabling closer placement of adjacent insulators.
Solution Approach 2:
The mounting openings are repositioned from a central location to an offset location in the transverse dimension. This allows the mounting hardware to interleave with adjacent insulators, reducing the overall space occupied by the insulator assembly while maintaining ease of installation.
Data Source
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AI summary
An insulator (30) is arranged to provide insulation between walls of an assembly and a bus bar which extend through the assembly. The insulator (30) comprises a contoured mounting member (32) having a contoured edge (38, 40), a bus bar-holding opening (44) extending through the mounting member (32), and mounting openings (48) provided on the mounting member (32). The mounting openings (48) are dimensioned to receive mounting hardware therein, and the mounting openings (48) are offset from the geometrical centerline of the bus bar-holding opening (44) by more than the radius of the mounting hardware.