Flexible Bus Bar Insulation for Bending Across Height Differences
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Solution Overview
Problem
Conventional bus bars lack flexibility, which prevents connection between members with height differences, and insulating methods impair flexibility or cause cracking when bending is required.
Innovation Solution
A flexible bus bar with a heat-shrinkable resin insulator that maintains flexibility by forming a hollow interior and avoiding contact with through holes, allowing shape changes without cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional rigid bus bar is used to connect members with height differences, then connection is possible only with precise height alignment, but flexibility and adaptability are lost
Solution Approach 1:
The bus bar is designed with a flexible structure comprising multiple link sections that can bend and adjust to different height differences between members. This dynamic configuration allows the bus bar to adapt to various installation scenarios without requiring precise height alignment, while maintaining ease of connection through simple bolting operations.
2Reliability
If the flexible bus bar is covered with liquid resin insulator to prevent electrical contact, then insulation is provided, but flexibility is impaired and cracking occurs during bending
Solution Approach 1:
The patent employs a flexible insulating coating or flexible insulating material that can bend with the bus bar without cracking. This flexible insulation layer maintains electrical isolation reliability while preserving the bus bar's ability to bend and adapt to height differences, avoiding the brittleness problem of liquid resin.
Solution Approach 2:
The bus bar utilizes composite material construction combining conductive material for electrical conduction with flexible insulating material for electrical isolation. This composite structure integrates both conductivity and flexibility requirements, allowing the bus bar to maintain its bending capability while providing reliable insulation protection.
3Power
If the bus bar is made thick and rigid to handle large currents, then current carrying capacity is sufficient, but flexibility and shape adaptability are reduced
Solution Approach 1:
The bus bar is divided into multiple link sections connected by joints or connectors. Each section can be optimized for current carrying capacity while the segmented structure provides overall flexibility. The segmentation allows the bus bar to maintain high power capability in each section while achieving shape adaptability through the articulated connection between sections.
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 flexible bus bar maintains its shape-changing ability and prevents current malfunctions when connecting members with height differences, ensuring reliable electrical connections.
Implementation Method 1
the insulator (3) is made of heat-shrinkable resin, and the flexible bus bar main body (2) is inserted into the hollow, and a part of the insulator (3) is heat-shrunk onto the inserted flexible bus bar main body (2), thereby fixing the part of the insulator (3)
Data Source
AI summary
A flexible bus bar that can maintain its flexibility even when covered with an insulator has a flexible bus bar main body having flexibility and an insulator covering a part of the flexible bus bar main body. The insulator has an interior S formed hollow, and the flexible bus bar main body is inserted into the hollow. Thereafter, a part of the insulator is heat-shrunk onto the inserted flexible bus bar main body, thereby fixing the part of the insulator.