Dual-Sided Bus Bar Mounting for High-Amperage Electrical Connections
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Solution Overview
Problem
Current electrical connections for high amperage components, such as relays or contactors, often lack sufficient voltage clamping area and mechanical support due to the limited interface surface area provided by bolted joints, which can be inadequate for high amperage applications exceeding 1000 Amperes.
Innovation Solution
An electrical assembly with dual side electrical interfaces utilizing captive mechanical connections, including a terminal block, conductors, and a bus bar with double-sided fasteners and notches, providing enhanced mechanical support and increased clamp area to handle high amperage and harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a bolted joint with a single electrical interface surface is used, then the mechanical support and electrical connection are provided, but the voltage clamping area is insufficient for high amperage applications exceeding 1000 Amperes
Solution Approach 1:
The patent transitions from a single-sided electrical interface to a dual-sided electrical interface configuration. The terminal block provides electrical connections on both sides of the conductor, effectively doubling the voltage clamping area available for high amperage applications while maintaining a manageable structural complexity through standardized terminal block design.
2Strength
If a single electrical interface surface is used, then the connection is simple, but the mechanical support is insufficient for high amperage components
Solution Approach 1:
The patent introduces a dual-sided fastening arrangement where fasteners are provided on both sides of the conductor. This distributes the mechanical support load across multiple attachment points, significantly enhancing the mechanical strength and stability of high amperage components while using standard fastener configurations that do not excessively increase device complexity.
3Power
If conventional bolted joints are used, then the installation is straightforward, but the assembly cannot effectively handle high amperage applications above 500 Amperes
Solution Approach 1:
The patent segments the electrical connection into multiple independent interface surfaces and fastening points distributed on both sides of the conductor. This segmentation allows the assembly to handle high amperage applications by distributing current across multiple contact surfaces, while each individual connection point remains straightforward to install using conventional fastening methods.
Solution Approach 2:
The dual-sided configuration adds a spatial dimension to the electrical connection, providing multiple parallel current paths that increase the overall current-carrying capability for high amperage applications while maintaining ease of installation through standardized terminal block and fastener configurations.
Data Source
Figure 1A~1B
Figure 2A~4
AI summary
An electrical assembly includes a first conductor (22), a second conductor (24), and a bus bar (26). The first conductor (22) is disposed on a terminal block and defines a first conductor opening. The second conductor (24) is spaced apart from the first conductor. The bus bar (26) extends from an electrical component. The bus bar (26) has a first bus bar surface that is arranged to engage the first conductor (22) and a second bus bar surface that is disposed opposite the first bus bar surface. The second bus bar surface is arranged to engage the second conductor. Each of the first bus bar surface and the second bus bar surface extends between an end surface of the bus bar (26) and the electrical component.