Busbar Conductor Openings to Prevent Bending Cracks
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Solution Overview
Problem
Busbar electric wires with flat rectangular cross-sections tend to experience compression and cracking when bent, leading to increased plate thickness and altered electrical characteristics, which can result in specification failures.
Innovation Solution
A conductor for busbar electric wire with a substantially rectangular cross-sectional shape featuring openings on one side in the width direction, which are filled by compression during bending, preventing plate thickness increase and reducing the likelihood of cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flat conductor with rectangular cross section is bent in the planar direction to match vehicle shape, then the wire can be wired according to vehicle shape, but the inner portion metal is compressed causing plate thickness increase and crack occurrence
Solution Approach 1:
The flat conductor is designed with a hollow internal structure containing air or gas, transforming the solid rectangular cross-section into a porous/腔体 structure. This hollow structure allows the internal space to expand during bending, accommodating the compression of the inner portion without increasing plate thickness, thereby preventing cracks while maintaining adaptability to vehicle shape
Solution Approach 2:
The invention introduces a new dimension by creating a hollow internal cavity within the flat conductor. This dimensional change from solid to hollow structure provides additional volume for deformation during bending, allowing the conductor to adapt to vehicle shapes without causing crack-inducing thickness increases in the inner portion
2Shape
If a flat conductor with rectangular cross section is bent in the planar direction, then the wire can be shaped, but the plate thickness of the inner portion increases leading to crack occurrence
Solution Approach 1:
The hollow internal structure provides void space that can be compressed during bending, absorbing the volume change that would otherwise manifest as plate thickness increase. This maintains precise control over plate thickness while enabling the desired bending shape
Solution Approach 2:
By introducing the hollow cavity dimension, the conductor gains internal volume for deformation. The bending-induced volume change occurs within the hollow space rather than increasing the outer plate thickness, thereby maintaining manufacturing precision while achieving the required shape
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 effectively prevents plate thickness increase and cracking during bending, maintaining electrical characteristics and ensuring the busbar electric wire can be reliably shaped to match vehicle forms without compromising performance.
Implementation Method 1
when the plate material is bent such that the one side becomes the inner side, the opening is filled by the compression of the inner side
Data Source
AI summary
A conductor for a busbar electric wire can include a conductive plate material having a substantially rectangular cross-sectional shape and an opening formed on one side in a width direction orthogonal to a longitudinal direction of the plate material. The width direction can correspond to a planar direction of the plate material. A busbar electric wire can include the conductor and an insulating sheath that covers the plate material.