Segmented Bus Bar Joints With Tolerance Buffers for Complex Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bus bars with a single member forming the wiring pathway face challenges in maintaining dimensional accuracy, especially when the pathway is complex, leading to manufacturing tolerances and reduced accuracy.
Innovation Solution
A bus bar composed of consecutively arranged conductive members with laser joining and tolerance buffers, where the connection surfaces of adjacent members have different widths, allowing for improved dimensional accuracy and flexibility in corresponding with various wiring pathways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single member is processed to form a complicated wiring pathway, then the bus bar can be manufactured as a single piece, but manufacturing tolerances are generated and dimensional accuracy with respect to the wiring pathway is reduced
Solution Approach 1:
The bus bar is divided into multiple members (first member, second member, third member) that are connected in sequence to form the wiring pathway. This segmentation allows each member to be manufactured with higher precision individually, while the overall complicated pathway is achieved through the combination of multiple precise segments rather than one complex single piece.
2Manufacturing precision
If multiple members are used to form the wiring pathway, then dimensional accuracy is improved, but the structure becomes more complex and requires connection processes
Solution Approach 1:
The tolerance buffer acts as an intermediary element between adjacent members with different widths. This intermediate structure absorbs dimensional variations and manufacturing tolerances, allowing the multiple members to be connected with high precision without requiring extremely tight tolerance control on each individual member, thereby simplifying the overall manufacturing process.
3Device complexity
If connection surfaces of adjacent members have the same width, then the structure is simple, but manufacturing tolerances cause displacement and reduce connection reliability
Solution Approach 1:
Adjacent members are designed with asymmetric connection surface widths, where one member has a wider connection surface than its adjacent member. This asymmetric design creates an overlapping connection area that acts as a tolerance buffer, absorbing dimensional variations and preventing displacement at connection points, thereby ensuring reliable electrical connections without increasing overall structural complexity.
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 solution enhances dimensional accuracy and electrical connection reliability by absorbing manufacturing tolerances, enabling the bus bar to effectively connect complex wiring pathways without displacement of connection points, thus ensuring stable and reliable electrical connections.
Implementation Method 1
the members adjacent to each other have connection surfaces at which the members adjacent to each other are connected to each other by laser joining
Data Source
AI summary
A bus bar includes members made from a conductive material and consecutively arranged to form a plate shape defining a wiring pathway. The members adjacent to each other have connection surfaces at which the members adjacent to each other are connected to each other by laser joining. The members adjacent to each other include at least one tolerance buffer between the members adjacent to each other. In the at least one tolerance buffer, the connection surfaces of the members adjacent to each other have different widths.