Busbar Connector Nested Within Conductive Plate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power connector systems increase the overall size and thickness of electrical systems due to exposed connectors, which are prone to damage, and lack a low-profile design.
Innovation Solution
A power connector system featuring a busbar connector recessed within the conductive plate of a busbar, allowing electrical components to be plugged into the interior, reducing the overall size and eliminating the need for external connectors, with the busbar connector and contact housed within the thickness profile of the conductive plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electrical connectors are mounted externally on the busbar, then electrical connectivity is achieved, but the overall size and thickness of the system increases
Solution Approach 1:
The busbar connector is nested within a cavity of the conductive plate, with the connector housing and contacts contained inside the plate thickness. This nesting approach reduces the overall system profile while protecting the connector components from external damage, resolving the contradiction between compact size and connector durability.
2Reliability
If electrical connectors are exposed along the side of the busbar, then connectivity is provided, but the connectors are susceptible to damage or breakage
Solution Approach 1:
The connector components are nested within the conductive plate cavity, providing mechanical protection while maintaining compact dimensions. The housing encloses the contacts and mating interface, shielding them from external damage sources.
Solution Approach 2:
The busbar connector housing acts as a protective shell that encloses the fragile contact components. This housing structure provides mechanical strength and protection while allowing the connector to maintain a low-profile design within the plate thickness.
3Volume of moving object
If the busbar connector is contained within the thickness profile of the conductive plate, then a lower profile is achieved, but the connector must be recessed into the busbar
Solution Approach 1:
The conductive plate is segmented to include an internal cavity that accommodates the busbar connector. This segmentation allows the connector to be recessed within the plate thickness, achieving a low-profile design while maintaining structural integrity through the cavity design.
Data Source
AI summary
A power connector system includes a busbar having a conductive plate. The conductive plate has first side and a second side. The conductive plate has a thickness profile between the first side and the second side. The conductive plate has a busbar opening therethrough between the first side and the second side. The power connector system includes a busbar connector received in the busbar opening of the conductive plate. The busbar connector includes a busbar housing and a busbar contact received in a socket of the busbar housing. The busbar housing is electrically conductive and electrically connected to the conductive plate in the busbar opening. The busbar contact is electrically conductive and electrically connected to the busbar housing in the socket. The busbar contact has a mating interface configured to mechanically and electrically connect to an electrical component plugged into the socket. The busbar housing and the busbar contact are both contained within the thickness profile of the conductive plate.