Busbar Nub Sealing and Low Resistance Connection
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Solution Overview
Problem
Existing electrical components with busbars between housing parts face challenges in achieving a watertight seal due to dimensional tolerances and result in high contact resistances from protruding connecting pins, leading to energy losses.
Innovation Solution
The busbar is designed with a nub and a circular contact ring end face section, featuring a through hole with a recess for a sealing ring, and a fastening element that extends through the nub for mechanical connection, ensuring a reliable seal and low contact resistance by direct contact with the power connection element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is provided between the cover and base plate to seal the busbar, then sealing reliability is improved, but device complexity increases and manufacturing becomes more difficult due to dimensional tolerances
Solution Approach 1:
The busbar is merged with the connecting pin to form an integrated connection element. The busbar extends through the housing and directly forms the external connection interface, eliminating the need for separate sealing structures and connecting pins. This integration simplifies the overall structure while maintaining reliable sealing through the direct extension of the busbar through the housing aperture.
2Ease of operation
If connecting pins are used to protrude from the housing for external connection, then ease of connection is improved, but contact resistance increases leading to energy losses
Solution Approach 1:
The busbar and connecting pin are merged into a single integral component. The busbar itself extends through the housing to form the external connection interface, eliminating the need for separate connecting pins. This direct extension provides both ease of connection and low contact resistance, as the electrical connection is made directly to the busbar without additional contact interfaces.
3Reliability
If separate sealing structures are added to achieve watertight seal, then sealing reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The busbar is integrated with the housing structure such that it extends directly through the housing aperture to form the external connection. This integration eliminates the need for separate sealing structures and reduces manufacturing precision requirements, as the busbar itself serves as both the electrical conductor and the sealing element through its direct extension through the housing.
Data Source
Figure 1
Figure 2~3
AI summary
An electrical component (10) is described, comprising at least one busbar (18) located between a first and a second housing part (12, 14), and which can be contacted with an external power connection element. The busbar (18) has a stud (22) projecting from its base (20), which has a circular contact ring end face section (26) and a circular cylindrical outer surface section (24). The stud (22) has a defined height dimension. The second housing part (14) has a hole (32) from which the stud (22) projects in a defined manner. The hole (32) of the second housing part (14) has a circumferential recess (36) in which a sealing ring (34) is provided. A fastening element (44) extends through a through hole (28) of the stud (22) and serves for the mechanically secure connection of the electrical connection element to the stud (22).