Bus Bar Assembly with Insulation Cutouts and Shroud

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Solution Overview

Problem

Conventional bus bar systems lack an efficient and secure method for forming and maintaining connections to terminals, which can lead to unreliable electrical connections and potential exposure to dust or fluid ingress.

Innovation Solution

A bus bar design featuring a conductive portion with insulation cutouts to expose terminals, combined with a header assembly that includes flanges and shroud walls to securely engage the bus bar, ensuring proper alignment and sealing of the terminal connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional bus bar systems use exposed protruding contacts at predetermined locations, then electrical connections can be formed, but the connections are unreliable and exposed to dust or fluid ingress

Engineering Contradiction:

Improveconnection reliabilityVSAvoiddust and fluid ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a header assembly with a shroud as an intermediary component between the external environment and the bus bar terminal. The shroud acts as a protective barrier that prevents dust and fluid from reaching the electrical connection interface, while still allowing the connection to be formed through the defined opening in the shroud.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The header shroud functions as a protective shell that encloses the terminal connection area. This shell structure provides physical protection against environmental contaminants while maintaining the electrical connectivity function through its designed opening, effectively isolating the connection from harmful external factors.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If conventional bus bar systems use simple terminal exposure, then manufacturing is simple, but the connection security and alignment are insufficient

Engineering Contradiction:

Improveconnection securityVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent divides the connection system into distinct functional segments: the bus bar with terminal, the header assembly with shroud, and the engagement portion with flanges. This segmentation allows each component to perform its specific function optimally - the bus bar provides electrical conductivity, the shroud provides protection, and the flanges provide secure mechanical engagement and alignment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The header assembly is pre-formed with the shroud and engagement portion integrated, allowing the bus bar to be inserted into a pre-prepared receptacle. The flanges are pre-positioned to engage with the bus bar insulation, ensuring proper alignment and secure attachment before the connection is made, rather than requiring complex assembly steps afterward.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If conventional bus bar systems use basic terminal exposure, then the structure is simple, but dust and fluid can easily enter the connection area

Engineering Contradiction:

Improveprotection from dust and fluidVSAvoidinsulation and shroud structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the insulation function and the protective shroud function into a single integrated header assembly. The shroud is formed as part of the header structure, combining the electrical insulation requirement with the environmental protection requirement in one component, rather than using separate insulation and protective covers.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The header assembly serves multiple functions simultaneously: it provides electrical insulation around the bus bar, creates a protective enclosure against dust and fluid, defines the connection interface opening, and includes engagement flanges for mechanical attachment. This multi-functionality reduces the need for multiple separate protective components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design enhances the formation and security of connections to bus bar terminals, preventing dust and fluid ingress while ensuring reliable electrical connections through frictional engagement and optional secondary locking mechanisms.

Implementation Method 1

ensuring proper alignment and sealing of the terminal connections through frictional engagement

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS10177513B1Bus bar assembly with a system to form and secure connections to the terminals on a bus bar

Publication Date: 2019.01.08 LEAR CORP

AI summary

A bus bar includes a conductive portion with a first face and an opposed second face. The first face and second face extend between a first edge and a second edge. The bus bar includes an insulation surrounding the conductive portion. The insulation includes a cut out where a portion of the insulation is removed to expose a terminal on the bus bar. The terminal includes part of the first face of the bus bar and part of the second face of the bus bar. The terminal is located between the first edge and the second edge of the bus bar.