DC Busway Electrical Connector for Same-Pole Current Balancing

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Solution Overview

Problem

Conventional DC busways experience unbalanced loads or currents in same-pole busbars due to differences in conductor lengths, contact resistance, and electrical loop lengths when power is taken from a plug interface in the middle of the loop.

Innovation Solution

An electrical connector with integrally formed conductors and conductive parts that allow same-pole busbars to be connected in parallel, featuring insulating assemblies and conductive parts to achieve current convergence, reducing temperature rise and improving heat conduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If power is taken from a plug interface position in the middle of the loop, then power can be supplied to loads such as a plug-in box, but the loads or currents of same-pole busbar downstream of the loop become unbalanced

Engineering Contradiction:

Improvepower supply capabilityVSAvoidcurrent balance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The electrical connector divides the busbar connection into multiple independent contact points (first conductor and second conductor separately contacting first busbar and second busbar). This segmentation allows current to be distributed through multiple parallel paths, balancing the load and preventing current unbalance when power is tapped from the middle of the loop.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrical connector establishes equipotential connections by providing parallel current paths through the first and second conductors. This ensures that both busbars maintain equal potential, preventing voltage drops and current unbalance that would otherwise occur due to differences in conductor lengths and contact resistances.

Inventive Principle:

Principle #12Equipotentiality

2Reliability

If conventional DC busway is provided with flanges at both ends of its loop, then same-pole busbars can be connected in parallel, but it is difficult to achieve current convergence at intermediate positions

Engineering Contradiction:

Improveparallel connectionVSAvoidconnection structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrical connector acts as an intermediary device that enables current convergence at intermediate positions along the busway loop. By introducing this mediator component with its pair of conductors and insulating assemblies, current can be effectively converged and redistributed without requiring complex modifications to the busway structure itself.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If integrally formed conductors are used, then current convergence is achieved and current balance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecurrent balanceVSAvoidconductor fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The first conductor and second conductor are integrally formed as a single piece, merging multiple functional elements into one component. This integration ensures consistent electrical properties and current distribution while simplifying the assembly process. The insulating assemblies are also integrated into the overall connector structure, reducing the total number of separate parts and simplifying manufacturing despite the integral formation requirement.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively balances currents in same-pole busbars, reducing temperature rise and improving heat conduction performance while maintaining electrical connectivity.

Implementation Method 1

since the conductor can conduct busbars on both sides, the same-pole busbar can be connected in parallel again at a position of the electrical connector through the conductor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

each of the pair of conductors is integrally formed, or each of the pair of conductors comprises at least one pair of conductive parts

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250350077A1Electrical connector and DC busway

Publication Date: 2025.11.13 SCHNEIDER ELECTRIC IND SAS

AI summary

Embodiments of the present disclosure provide an electrical connector and a DC busway, the electrical connector comprising a pair of conductors; a first insulating assembly disposed between the pair of conductors; and a pair of second insulating assemblies each disposed on a side of the pair of conductors facing away from the first insulating assembly; wherein each of the pair of conductors is integrally formed, or each of the pair of conductors comprises at least one pair of conductive parts.