Busbar Connection Structure With Balanced Heat Sheet Counterforce
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Solution Overview
Problem
Existing busbar connection structures face issues with compactness and balance due to the need for multiple terminal blocks and uneven counterforces from heat transfer sheets, leading to potential tilting or warping of terminal blocks.
Innovation Solution
A busbar connection structure with a terminal block having fastened parts on both sides and interposed heat transfer sheets between these parts and the cooling section, allowing balanced counterforce application and reducing the need for multiple terminal blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single terminal block is used with one fastened part, then the device complexity is reduced, but the counterforce balance deteriorates causing tilting or warping
Solution Approach 1:
The terminal block is segmented into multiple functional parts: a fastening part for mechanical attachment and multiple fastened parts for electrical connections. This segmentation allows the single terminal block to handle multiple busbars while maintaining structural stability through balanced counterforce distribution from heat transfer sheets at each fastened part.
Solution Approach 2:
Multiple fastened parts are merged into a single terminal block body, allowing one terminal block to electrically connect multiple busbars simultaneously. This combining approach reduces the total number of terminal blocks needed while maintaining stability through symmetric heat transfer sheet placement.
2Ease of manufacture
If heat transfer sheets are placed only on one side, then the manufacturing process is simplified, but the counterforce application becomes unbalanced causing terminal block tilting
Solution Approach 1:
The terminal block design accommodates asymmetric placement of heat transfer sheets relative to the terminal block body, while achieving symmetric counterforce distribution. Heat transfer sheets are positioned at each fastened part regardless of their location relative to the terminal block center, ensuring balanced force application.
Solution Approach 2:
Heat transfer sheets are selectively placed at each fastened part based on local requirements for heat dissipation and force balance, rather than applying a uniform placement rule throughout. This local quality approach ensures optimal counterforce distribution while maintaining manufacturing simplicity.
3Reliability
If multiple terminal blocks are used for each busbar connection part, then the electrical connection reliability is improved, but the overall structure becomes less compact
Solution Approach 1:
Multiple terminal blocks are merged into a single integrated terminal block that can electrically connect multiple busbars simultaneously. The terminal block body integrates multiple fastened parts, each capable of securing a busbar, thereby maintaining high electrical connection reliability while significantly reducing the overall volume and complexity of the connection structure.
Solution Approach 2:
The terminal block is designed with universal functionality to handle multiple busbar connections through its multiple fastened parts. Each fastened part can independently secure a busbar while sharing the common terminal block body and fastening mechanism, achieving multi-functionality that reduces the number of separate components needed.
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 configuration results in a more compact and stable busbar connection structure that prevents tilting or warping while allowing efficient heat transfer and electrical insulation.
Implementation Method 1
The heat transfer sheet is an insulator interposed between the fastened part and the cooling section. This allows the connection part of the busbars to be physically connected to the cooling section via the fastened part and the heat transfer sheet and capable of transferring heat to the cooling section.
Data Source
AI summary
The objective is to render a busbar connection structure compact while allowing the counterforce from a heat transfer sheet pushing back fastened parts to be applied to a fastening part in a well-balanced manner. The busbar connection structure includes a fastening part, fastened parts, and a heat transfer sheet. The fastening part fastens the terminal block body to the cooling section. The first fastened part is a conductor attached to one side of the fastening part in the terminal block body. The connection part of the busbars is fastened to the first fastened part. The second fastened part is a conductor attached to another side of the fastening part. The connection part of the busbar is fastened to the second fastened part. The heat transfer sheet is an insulator interposed between the first fastened part and the cooling section, and between the second fastened part and the cooling section.