Flexible Busbar Structure for Foldable Automotive Installation
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Solution Overview
Problem
Current automotive busbars face challenges in installation due to their rigid nature, which makes it difficult to fold and unfold them into compact shapes within tight vehicle spaces without causing plastic deformation, leading to improper fitting.
Innovation Solution
An automotive busbar design featuring a flexible section made from a higher conductivity material than the rigid sections, with a smaller cross-sectional area and voids on its surfaces, allowing for compact folding and precise re-shaping without deformation, along with a flexible insulation coating for vibration absorption and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the busbar is made from rigid metallic material, then it can support its own weight and withstand mechanical vibrations, but it cannot be folded into compact shapes for insertion within tight automobile spaces
Solution Approach 1:
The busbar is divided into multiple sections with different mechanical properties: rigid sections for structural support and vibration resistance, and flexible sections for enabling folding during installation. This segmentation allows each portion to perform its specific function optimally.
Solution Approach 2:
Different sections of the busbar have different material compositions and cross-sectional areas. The flexible sections have reduced cross-sectional area and different material properties compared to rigid sections, creating local variations in mechanical properties that enable folding while maintaining overall structural integrity.
2Ease of operation
If the busbar is bent or folded to compact shape for insertion, then it can be installed within tight spaces, but plastic deformation occurs resulting in undesirable profiles when bent back
Solution Approach 1:
The flexible sections incorporate voids or hollow structures within the metallic material, creating a flexible shell-like structure that can bend and fold without causing plastic deformation. This allows the busbar to be folded for installation and then returned to its original shape with minimal deformation.
Solution Approach 2:
The flexible sections contain voids or porous structures that reduce material density and increase flexibility. These voids allow the section to deform elastically during folding and unfolding operations, preventing permanent plastic deformation and maintaining shape precision.
3Adaptability or versatility
If the flexible section has smaller cross-sectional area, then it allows easier folding, but electrical conductivity may be reduced
Solution Approach 1:
The flexible section uses different material composition and cross-sectional area parameters compared to rigid sections. By carefully selecting material properties and dimensions, the design achieves the necessary flexibility while maintaining adequate electrical conductivity for the application.
Solution Approach 2:
The busbar employs composite construction with different metallic materials in different sections. The flexible sections use materials and structures optimized for flexibility, while rigid sections use materials optimized for structural support, creating a composite structure that balances electrical, mechanical, and installation requirements.
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
Enables the busbar to be easily folded and secured within tight spaces without undesirable profiles, ensuring precise fitting and efficient electrical conductivity while withstanding mechanical vibrations.
Implementation Method 1
a flexible section positioned between and interconnecting the first and second rigid sections, the flexible section made from a second conductive metallic material... allowing for compact folding and precise re-shaping without deformation
Implementation Method 2
the second conductive material has a higher conductivity than the first conductive material
Implementation Method 3
along with a flexible insulation coating for vibration absorption and protection
Data Source
AI summary
An automotive busbar includes a first rigid section and a second rigid section, each of the first and second rigid sections formed from a first conductive metallic material and having a first effective cross-sectional area, and a flexible section positioned between and interconnecting the first and second rigid sections, the flexible section made from a second conductive metallic material and having a second effective cross sectional area, and a top surface and a bottom surface, at least one of the top and bottom surface including a plurality of voids formed therein and spaced along the flexible section, wherein, the second effective cross-sectional area is less than the first effective cross-sectional area and the second conductive material has a higher conductivity than the first conductive material.