Bus Bar Terminal Connector Current Shaping

The patent applies local quality by creating non-uniform gap distributions in the terminal connector. Specifically, gaps between adjacent terminals are varied in size - some gaps are larger while others are smaller - to compensate for differences in terminal impedances. This localized adjustment of gap dimensions ensures that current flow is balanced across all terminals, preventing uneven power losses while maintaining reliable electrical connections.

The patent employs parameter changes by systematically varying gap dimensions between terminals based on their specific impedance characteristics and thermal requirements. Each gap is designed with a specific width and length to achieve desired current distribution and thermal balance. This parameter optimization prevents excessive thermal stress that would otherwise cause delamination and debonding, while the overall connector structure remains relatively simple.

The patent implements local quality by introducing controlled variations in gap dimensions at specific terminal locations. Rather than using uniform gaps throughout, the design specifies different gap sizes based on local electrical requirements - larger gaps where impedance is lower and smaller gaps where impedance is higher. This localized customization achieves precise electrical balance while remaining compatible with standard manufacturing processes.

The patent applies parameter changes by optimizing gap dimensions to balance current distribution and reduce thermal stress concentrations. The gap sizes are specifically calculated to ensure that high current flow does not create excessive localized heating. By distributing current more evenly across terminals through controlled gap variations, the design handles high power while minimizing thermal fatigue that would lead to fatigue cracking.