Busbar Connector Assembly for Gap-Free Thermal Dissipation
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Solution Overview
Problem
In conventional connectors with ceramic insulating members, tiny gaps can form between the busbar and the housing due to dimensional errors and differences in thermal expansion coefficients, leading to increased thermal contact resistance and impaired heat dissipation.
Innovation Solution
A connector design featuring a metal housing with flat plate-like busbars, first and second ceramic members with high thermal conductivity interposed between the busbar surfaces and housing contact portions, and a fastening member to collectively secure the busbar, ceramic members, and housing contact portions, ensuring continuous thermal contact without gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a ceramic member is merely placed adjacent to the busbar and the housing, then the structure is simple, but tiny gaps form due to dimensional errors and thermal expansion differences, increasing thermal contact resistance
Solution Approach 1:
The patent applies preliminary action by pre-configuring the ceramic member with recessed portions that anticipate and accommodate dimensional variations and thermal expansion differences between the busbar and housing. The recesses are designed in advance to ensure continuous contact despite manufacturing tolerances and thermal effects, preventing gap formation before they occur.
Solution Approach 2:
The patent employs parameter changes by modifying the geometric parameters of the ceramic member, specifically introducing recessed portions with specific depths and dimensions. These parameter adjustments allow the ceramic member to adapt to thermal expansion coefficients differences and dimensional errors, maintaining reliable thermal contact under varying conditions.
2Ease of operation
If the ceramic member is merely placed adjacent to the busbar and housing, then assembly is easy, but thermal contact resistance increases due to gap formation
Solution Approach 1:
The recessed portions are designed in advance to ensure that the ceramic member maintains contact with both the busbar and housing without requiring complex assembly procedures. This preliminary configuration allows for easy assembly while preventing gap formation that would otherwise increase thermal contact resistance and reduce heat dissipation efficiency.
Solution Approach 2:
The patent uses a composite structure combining the ceramic member with recessed portions that interface with both the metallic busbar and housing. This composite design leverages the high thermal conductivity of ceramic materials while the recessed geometry ensures continuous thermal contact, maintaining energy efficiency without complicating assembly.
3Ease of manufacture
If dimensional errors and thermal expansion differences are not compensated, then manufacturing is simpler, but gaps form between components, deteriorating heat dissipation
Solution Approach 1:
The patent applies parameter changes by designing the ceramic member with recessed portions having specific geometric parameters that compensate for dimensional errors and thermal expansion differences. These parameter modifications allow the structure to accommodate manufacturing variations and thermal effects without requiring complex manufacturing processes, maintaining both simplicity and heat dissipation performance.
Solution Approach 2:
The patent directly addresses thermal expansion by designing the recessed portions of the ceramic member to accommodate differences in thermal expansion coefficients between the busbar, ceramic, and housing. The recesses provide clearance that prevents gap formation when materials expand or contract with temperature changes, ensuring continuous thermal contact and maintaining productivity.
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 described connector configuration effectively maintains continuous thermal contact between the busbar and the housing, enhancing heat dissipation and reducing thermal contact resistance.
Implementation Method 1
a first ceramic member to be interposed between one flat surface of the busbar and a first contact portion of the housing, a second ceramic member to be interposed between another flat surface of the busbar and a second contact portion of the housing
Data Source
AI summary
One aspect of the present disclosure is to provide a connector enabling good heat dissipation. A connector 11 according to the one aspect of the present disclosure is provided with a housing 13 made of metal, a flat plate-like busbar 14 to be held in the housing 13, a first ceramic member 18 to be interposed between one flat surface 14a of the busbar 14 and a first contact portion 17 of the housing 13, a second ceramic member 20 to be interposed between another flat surface 14a of the busbar 14 and a second contact portion 19 of the housing 13, and a bolt 21 and a nut 22 for collectively fastening the busbar 14, the first and second ceramic members 18, 20 and the first and second contact portions 17, 19.