Embossed Parallel Busbar Structure for Better Heat Dissipation

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Solution Overview

Problem

Conventional busbars in low, medium, and high voltage applications suffer from inefficiencies in heat dissipation due to the skin effect, bulkiness, and complexity in assembly, particularly when multiple parallel bars are used, which results in increased weight and complexity.

Innovation Solution

A busbar design comprising a plurality of bar elements with raised sections or embossments that allow spacing without additional spacers, enhancing convective and radiative cooling, and simplifying assembly by integrating these features into the bar elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If two parallel bars are used for high-current applications, then the current carrying capacity is improved, but the device complexity increases due to the need for additional spacers and connecting means

Engineering Contradiction:
Improvecurrent carrying capacityVSAvoidassembly complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The spacer function is merged into the bar element itself by creating raised sections or embossments that are integral parts of the bar. This eliminates the need for separate spacer components and reduces assembly complexity while maintaining the required spacing between parallel bars for heat dissipation.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The raised sections on the bar elements serve multiple functions: they act as spacers to maintain distance between parallel bars, provide mounting surfaces for connecting means, and increase the surface area for convective and radiative cooling. This multi-functionality reduces the number of separate components needed.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Temperature

If spacers are added between parallel bars to maintain distance, then the heat dissipation is improved, but the weight and material usage increase

Engineering Contradiction:
Improveheat dissipationVSAvoidbusbar weight
Core Design Contradiction:
TemperatureVSWeight of stationary object

Solution Approach 1:

The spacer function is combined with the bar element structure itself through raised sections or embossments. This eliminates the need for additional spacer materials and reduces overall weight while maintaining adequate spacing for heat dissipation between parallel bars.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

Instead of adding separate spacer components in the space between bars, the spacing function is achieved by modifying the dimensionality of the bar elements themselves through raised sections. This uses the vertical dimension of the bar cross-section to provide spacing, eliminating the need for additional horizontal spacer materials.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Power

If single bars of large cross-section are used, then the current carrying capacity is improved, but the heat dissipation surface area is limited

Engineering Contradiction:
Improvecurrent carrying capacityVSAvoidheat dissipation surface area
Core Design Contradiction:
PowerVSArea of stationary object

Solution Approach 1:

Instead of using a single large cross-section bar, the busbar is segmented into multiple parallel bars of smaller cross-section. This segmentation increases the total surface area available for heat dissipation through convection and radiation while maintaining the required current carrying capacity through the parallel configuration.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The design transitions from a single large cross-section to multiple smaller cross-sections arranged in parallel, utilizing the spatial arrangement in another dimension. This configuration increases the exposed surface area for heat dissipation while maintaining equivalent or improved current carrying capacity through the parallel path arrangement.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 design improves heat dissipation through increased surface area, reduces weight, and simplifies assembly by eliminating the need for additional spacers, leading to more efficient cooling and reduced material usage.

Implementation Method 1

The heat is transferred to the ambient environment by convection and radiation

Methodology Applied
Scientific EffectConvection: Convection

Implementation Method 2

The heat is transferred to the ambient environment by convection and radiation

Methodology Applied
Scientific EffectRadiation: Radiation

Implementation Method 3

The flowing current generates heat due to resistivity of the used material (e.g., cooper and aluminum)

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 4

With respect to alternating current flow, the skin effect pushes the current density to the surface of these bars

Methodology Applied
Scientific EffectSkin effect: Skin Effect

Data Source

PatentUS12494623B2Busbar for a low voltage, medium voltage, or high voltage switchgear
Publication Date: 2025.12.09 ABB (SCHWEIZ) AG
  • US12494623B2 patent drawing
  • US12494623B2 patent drawing

AI summary

A busbar includes a plurality of bar elements having a first bar element and a second bar element; wherein the first bar element comprises a first surface and a second surface opposite to the first surface; wherein the first bar element comprises at least one raised section or embossment protruding out from the first surface; wherein the second bar element comprises a first surface and a second surface opposite to the first surface; and wherein the first bar element is connected to the second bar element, wherein the first surface of the first bar element faces towards the first surface of the second bar element.