Flexible Busbar Device for Backplane Power Distribution
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Solution Overview
Problem
Conventional backplane systems face challenges in providing high-power current efficiently, leading to increased production costs and potential deformation due to the need for precise mounting and high-layer copper configurations, which complicates maintenance and reliability.
Innovation Solution
A flexible busbar device with mounting holes spaced wider than those on the backplane, allowing for convenient mounting and detachment without deforming the backplane, and reducing the need for precise hole alignment, thereby simplifying the manufacturing process and maintaining system reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple layers of integral copper sheets are added to the multilayer PCB to provide high-power current, then the current supply capacity is improved, but the production cost increases significantly
Solution Approach 1:
The invention divides the power supply function into two parts: the multilayer PCB provides grounding reference and signal interconnection, while a separate busbar structure provides the high-power current supply. This segmentation allows each component to be optimized independently, avoiding the need to increase PCB layer count for power delivery.
Solution Approach 2:
The invention introduces base pins as intermediary connection elements between the busbar and the PCB. These base pins enable electrical connection without requiring the PCB itself to carry the full power load, thus protecting the PCB from deformation while achieving high-power delivery.
2Power
If the layer number of the backplane is increased to provide high-power current, then the current supply capacity is improved, but the production cost increases at a rate greater than the layer number increment
Solution Approach 1:
The invention separates the power delivery function from the PCB structure by using an independent busbar assembly. This allows the PCB to maintain its original layer configuration for signal and grounding functions, while power delivery is achieved through the external busbar structure with base pin connections.
3Power
If copper is laid partially on the signal plane or power is supplied to divided areas of the ground plane, then the current supply is improved, but the wiring space decreases and wiring difficulty increases
Solution Approach 1:
The invention extracts the power delivery function from the PCB's signal and ground planes by introducing a separate busbar structure. This extraction preserves the full wiring space and simplicity of the original PCB layout while achieving the required power delivery capacity through the external busbar system.
4Power
If a long press-fitted busbar is used to extend through the whole backplane, then the current supply coverage is improved, but the backplane may be deformed and maintenance becomes inconvenient
Solution Approach 1:
The invention divides the busbar into multiple separate sections, each connected to the PCB at different locations through base pins. This segmentation prevents the busbar from acting as a long rigid object that could deform the PCB, while still providing comprehensive power supply coverage across the entire backplane area.
Solution Approach 2:
The invention makes the busbar system dynamically adjustable by using removable base pins that can be pressed in for connection and removed for maintenance. This dynamic connection method allows the busbar to adapt to PCB thermal expansion and contraction without causing deformation, while enabling easy maintenance by removing individual base pins.
5Reliability
If base pins are closely contacted with conductors in large areas through press-fitted process, then the electrical connection is improved, but the base pins may be embedded into the metal and removal becomes difficult
Solution Approach 1:
The invention creates a dynamic press-fit connection where base pins can be easily inserted and removed. The base pins are designed with dimensions that allow them to be pressed into the PCB for electrical connection and then removed by applying external force, enabling maintenance while maintaining reliable electrical contact during operation.
Data Source
AI summary
A busbar device includes a conductive body. The conductive body is provided with a number of mounting holes corresponding to the mounting holes of a mount device for mounting the busbar device. The conductive body is a flexible conductive body, and the distance between every two adjacent mounting holes in the conductive body is larger than or equal to the distance between two corresponding adjacent mounting holes in the mount device.