Busbar Connection Structure With Conductive Grease and Bolt Locking
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Solution Overview
Problem
Existing busbar connection structures face challenges in enhancing electrical and heat conductivity while preventing bolt loosening due to vibrations, as applying grease to improve conductivity is impractical due to the risk of grease entering thread holes and causing bolts to loosen.
Innovation Solution
A busbar connection structure that includes a terminal block, a fastened base with a thread hole, a heat transfer sheet for insulation, a bolt threaded into the thread hole, electrically conductive grease applied between the busbars and the fastened base, and a thread locking member to prevent bolt loosening by biting into the thread hole surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically conductive grease is applied to the connection part of the busbars to improve electrical conductivity and heat conductivity, then the electrical conductivity and heat conductivity are improved, but the grease may enter the thread holes and cause the bolts to loosen under external disturbances such as vibrations
Solution Approach 1:
The connection structure is divided into separate functional zones: the grease application area (connection part between busbars and fastened base) is segmented from the thread hole area. This spatial segmentation allows grease to be applied where conductivity is needed without contaminating the thread holes, thus preventing bolt loosening while maintaining electrical and thermal conductivity.
Solution Approach 2:
The patent introduces an intermediary structure (the fastened base with its top surface and side surface) that mediates between the grease application and the thread hole. The grease is applied to the top surface and side surface of the fastened base, which act as intermediate surfaces that provide conductivity pathways without directly contacting the thread hole interior, thus preventing grease from entering the thread holes.
2Temperature
If grease is applied between the busbars and the fastened base to enhance heat transfer, then the heat conductivity is improved, but the bolt may loosen due to grease entering the thread hole under vibrations
Solution Approach 1:
The fastened base structure segments the heat transfer path from the bolt fixation path. The top surface and side surface of the fastened base form dedicated heat transfer interfaces that are spatially separated from the thread hole, allowing grease to be applied for thermal conductivity without risking bolt loosening.
Solution Approach 2:
The fastened base acts as an intermediary component that receives grease on its external surfaces (top and side surfaces) for heat transfer purposes, while its internal thread hole remains protected. This intermediary structure enables thermal enhancement without compromising mechanical fastening reliability.
3Temperature
If the connection part is physically connected to the cooling section via the fastened base to enable heat transfer, then the heat transfer efficiency is improved, but the electrical insulation between the busbars and the cooling section must be maintained
Solution Approach 1:
The connection structure is segmented into electrically conductive paths and electrically insulating paths. The fastened base and grease provide conductive paths for heat transfer from busbars to cooling section, while the terminal block body and heat transfer sheet provide insulating paths that prevent electrical current flow to the cooling section. This spatial segmentation of functional paths enables simultaneous heat transfer and electrical insulation.
Solution Approach 2:
The terminal block body and heat transfer sheet act as intermediary insulating components between the conductive fastened base and the cooling section. These intermediaries allow thermal energy to pass through (via conduction through the fastened base) while blocking electrical current, thus enabling heat transfer while maintaining electrical insulation.
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 configuration improves electrical and heat conductivity between busbars and the fastened base while preventing bolt loosening, ensuring reliable connections under external disturbances.
Implementation Method 1
electrically conductive grease applied in an area of the connection part, the area including an area between the busbars and an area between the busbar and the fastened base
Implementation Method 2
electrically conductive grease applied in an area of the connection part, the area including an area between the busbars and an area between the busbar and the fastened base
Implementation Method 3
a heat transfer sheet as an insulator interposed between the fastened base and the cooling section
Implementation Method 4
a thread locking member interposed between an outer circumferential surface of the bolt and an inner circumferential surface of the thread hole, the thread locking member suppressing loosening of the bolt in the thread hole by biting into the outer circumferential surface and the inner circumferential surface
Data Source
AI summary
The objective is to improve the electrical conductivity and heat conductivity at the connection part of the busbars while suppressing the loosening of bolts. The busbar connection structure includes a terminal block body, a fastening part, a fastened base, a bolt, grease, and a thread locking member. The fastening part fastens the terminal block body to the cooling section. The fastened base is attached to the terminal block body and includes a thread hole. The bolt fastens the connection part of the busbars to the fastened base. The grease is electrically conductive and is applied at the connection part of the busbars. The thread locking member is interposed between the outer circumferential surface of the bolt and the inner circumferential surface of the thread hole, and suppresses the loosening of the bolt by biting into the outer and inner circumferential surfaces.