Stacked Flexible Electrical Bus Bar with Hinge Links
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Solution Overview
Problem
Electrical bus bars for high current applications in vehicles face challenges in mechanical flexibility and manufacturing complexity, particularly in limited spaces and varying battery positions, requiring a solution that balances flexibility and high current carrying capacity while being easy and cost-effective to manufacture.
Innovation Solution
A stacked configuration of flat metal parts with links acting as hinges, allowing for assembly flexibility and high current conductivity, manufactured using a single metal sheet and stamping process, with tin and silver plating for reduced resistance and corrosion protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a high number of thin electrical conductors are used to provide flexibility, then mechanical flexibility is improved, but current carrying capacity deteriorates
Solution Approach 1:
The bus bar is divided into multiple flat parts (at least two) that are stacked and connected by links. Each flat part can move relative to others through the hinge-like links, providing flexibility. Meanwhile, the stacked configuration with intimate contact surfaces maintains low electrical resistance for high current capacity.
Solution Approach 2:
The bus bar combines multiple flat metal parts stacked together with links forming a composite structure. This composite design integrates the flexibility of segmented components with the high current carrying capability of solid metal construction, achieving both flexibility and electrical performance.
2Quantity of substance
If the thickness of the bus bar is increased to carry high currents, then current carrying capacity is improved, but manufacturing complexity and cost deteriorate
Solution Approach 1:
Instead of manufacturing one thick bus bar, the invention segments it into multiple thinner flat parts that are stacked and connected. This segmentation simplifies manufacturing of individual components while achieving the required current capacity through the combined cross-sectional area of all flat parts.
Solution Approach 2:
Multiple flat parts are merged into a stacked configuration with intimate contact surfaces, creating a unified electrical conductor. The links merge the flat parts mechanically while maintaining electrical continuity, achieving high current capacity without the complexity of manufacturing a single thick component.
3Quantity of substance
If solid flat parts are used to carry high currents, then current carrying capacity is improved, but mechanical flexibility deteriorates
Solution Approach 1:
The bus bar structure is made dynamic by introducing links that allow the flat parts to move relative to each other. The links act as hinges enabling folding and adjustment, transforming a rigid solid structure into a flexible dynamic system that can adapt to varying positions while maintaining electrical contact.
Solution Approach 2:
Links serve as intermediary elements between the solid flat parts. These intermediaries enable relative movement between the flat parts while maintaining both mechanical connection and electrical continuity, allowing flexibility without compromising current carrying capacity.
4Adaptability or versatility
If multiple flat parts are stacked to provide flexibility, then mechanical flexibility is improved, but contact surface stability deteriorates
Solution Approach 1:
The links are designed to maintain intimate contact between flat parts throughout their range of motion. By pre-configuring the link geometry and connection points, the structure ensures stable electrical contact is maintained even when flat parts move relative to each other, cushioning against contact instability.
Solution Approach 2:
The invention replaces rigid mechanical fixation with a hinge-based link system that maintains electrical contact through controlled movement. The links substitute traditional rigid mounting with a flexible mechanical system that preserves contact stability while enabling necessary adjustments for assembly tolerances.
Data Source
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AI summary
An electrical bus bar (10) comprising: a first mounting portion (110) adapted to be connected to a first counter connector, a second mounting portion (120) adapted to be connected to a second counter connector and a flexible section (130) between the first and second mounting portions (110, 120), wherein the bus bar (10) comprises at least a flat first part (140) and at least a flat second part (150), wherein each flat part (140, 150) extends from the first mounting portion (110) to the second mounting portion (120) and is arranged in a stacked configuration, wherein the flat first part (140) and the flat second part (150) is made of a metal sheet (30), wherein a first stripe (180) of the metal sheet (30) extends from a body edge of the flat first part (140) to a body edge of the flat second part (150) forming a first link (181), wherein the first link (181) is dimensioned to keep a first contact surface (142) of the flat first part (140) and a second contact surface (152) of the flat second part (150) in intimate contact.