Single-Row Busbar Connector Crimping for Lower Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing busbar connectors face challenges in heat dissipation and current carrying capacity due to insufficient crimping and contact resistance when multiple cables are connected, leading to reduced efficiency.
Innovation Solution
A busbar connector design featuring a housing with upright portions, terminal sets with crimping portions having a cross-sectional aspect ratio greater than or equal to 3, and cables arranged in a single row to increase contact and heat dissipation areas, reducing contact resistance and enhancing heat dissipation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple cables are crimped in multiple rows on the power terminal, then the cable connection capacity is improved, but the crimping force required increases and contact resistance is not reduced
Solution Approach 1:
The patent transitions from multi-row cable arrangement to a single-row arrangement with optimized crimping portion geometry. The crimping portion is designed with an aspect ratio (length-to-width ratio) of 3:1 or greater, extending in the direction perpendicular to cable arrangement. This dimensional change allows multiple cables to be crimped in a single row with reduced crimping force while maintaining connection capacity.
2Quantity of substance
If multiple cables are crimped in multiple rows on the power terminal, then the cable connection capacity is improved, but contact resistance increases due to gaps between copper wires and crimped portion
Solution Approach 1:
The patent extends the crimping portion in the direction perpendicular to the cable arrangement, creating a high aspect ratio structure (3:1 or greater). This dimensional extension increases the contact area between the crimping portion and the cables, eliminating gaps and reducing contact resistance while maintaining the ability to connect multiple cables.
Solution Approach 2:
The crimping portion is designed with differentiated local characteristics - it extends significantly in the direction perpendicular to cable arrangement (aspect ratio ≥ 3:1), creating localized high-contact-area regions that specifically address the contact resistance issue at the cable-interface while maintaining overall connection capacity.
3Ease of manufacture
If traditional crimping structure is used, then manufacturing simplicity is maintained, but heat dissipation efficiency is reduced due to insufficient contact area and heat dissipation surface
Solution Approach 1:
The crimping portion is extended in the direction perpendicular to cable arrangement, creating a high aspect ratio structure. This dimensional change simultaneously increases both the contact area with cables and the heat dissipation surface area exposed to air, improving heat dissipation efficiency without complicating the manufacturing process.
Solution Approach 2:
The crimping portion is designed with localized extended geometry that specifically increases heat dissipation surface area in the direction perpendicular to cable arrangement. This local quality enhancement focuses heat dissipation capability where needed while maintaining manufacturing simplicity.
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 design improves current carrying capacity and heat dissipation efficiency by increasing contact areas and heat dissipation surfaces, while reducing contact resistance and insertion force requirements.
Implementation Method 1
contact areas between the crimp portion of the power terminal and the cables can be increased to reduce contact resistance
Implementation Method 2
surface areas of each of the cables that are in contact with the air can be increased (i.e., the heat dissipation area are increased), thereby improving heat dissipation efficiency
Data Source
AI summary
A busbar connector includes a housing, two terminal sets, and a plurality of cables. The housing includes two upright portions, and the two upright portions are opposite to each other and jointly form the socket. The two terminal sets are inserted into the housing. Each of the terminal sets includes at least one power terminal. The at least one power terminal includes a contact portion, a fixing portion, and a crimping portion. The fixing portion is connected between the contact portion and the crimping portion. The plurality of cables are arranged in a single row, and one end of the plurality of cables is fixedly connected to the crimping portion. The crimping portion has a cross section that is perpendicular to an extending direction of the plurality of cables, and an aspect ratio of the cross section is greater than or equal to 3.