Pipe-shaped bus bar with segmented conductors for connector insertion
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Solution Overview
Problem
Conventional bus bars produced by punching metallic plates result in low material yield and require numerous process steps for terminal screwing, leading to inefficiencies in production and assembly.
Innovation Solution
A bus bar and connector design featuring a pipe-shaped bus bar core conductor with alternately arranged conductors and insulators, allowing for easy electrical connection by inserting the bus bar into a recessed connector, reducing the need for screw fixation and minimizing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If plate-shaped bus bars are produced by punching metallic plates, then electrical connection capability is achieved, but metal material yield is low and material waste is high
Solution Approach 1:
The bus bar is divided into multiple conductors (core conductor and outer conductors) arranged in specific patterns, allowing optimized material usage while maintaining electrical performance. This segmentation enables precise control over material distribution and reduces waste compared to solid plate construction.
Solution Approach 2:
The invention transitions from a two-dimensional plate structure to a three-dimensional multi-conductor arrangement. By utilizing spatial distribution of conductors in radial and axial directions, the design achieves better material efficiency and electrical performance without requiring excessive material.
2Productivity
If terminals are connected by screw fixation, then reliable electrical connection is achieved, but the number of process steps increases
Solution Approach 1:
The connector integrates multiple functions into a single component: it provides both mechanical support and electrical connection pathways. The connector body combines insulating structure with embedded contact elements, eliminating the need for separate terminal pieces and screw fasteners while maintaining reliable electrical connectivity.
Solution Approach 2:
The invention replaces the mechanical screw fixation system with a snap-fit or insertion-based connection mechanism. The connector is designed to receive and secure the bus bar assembly through dimensional compatibility and elastic retention features, eliminating the need for threading and fastening operations.
3Temperature
If plate-shaped bus bars are used, then heat dissipation capability is achieved, but the number of screwing process steps increases
Solution Approach 1:
The connector design merges the electrical connection function with the mechanical attachment function, eliminating separate screwing operations. The integrated structure provides both thermal management pathways and secure mechanical retention without requiring additional fastening steps.
Solution Approach 2:
The connector is pre-designed with built-in retention features and alignment guides that automatically secure the bus bar assembly upon insertion. This preliminary configuration of retention mechanisms eliminates the need for subsequent screwing operations to achieve mechanical attachment.
Data Source
AI summary
A projected end of a bus bar (20), including projection portions (21A, 22B, 23C, 24D, 25E, 26F), and a recessed connector (30), including a cylindrical portion (43A), a recess portion (31B), a cylindrical portion (42C), a recess portion (31D), a cylindrical portion (41E), and a recess portion (31F), are engaged with each other, thereby enabling the bus bar (20) and the connector (30) to electrically connect with each other. That is, only inserting the bus bar (20) into the connector (30) makes an electrical connection possible, so it is not necessary, for example, to fasten the terminal with a screw. Therefore, this facilitates the connection between the bus bar (20) and the connector (30).