Flexible Electrical Busway Coupling Assembly

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Solution Overview

Problem

Existing electrical busway systems are inflexible and require complex, bulky termination boxes for connection, which are labor and cost-intensive and do not meet regulatory standards for grounded metal enclosures, limiting their application and configurability.

Innovation Solution

A flexible coupling assembly for electrical busways that includes a grounded, flexible housing with coupling members and insulators, allowing for electrical connection between sections without separate termination boxes, meeting regulatory standards for grounded metal enclosures and enabling easy reconfiguration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If rigid bus bars are used to connect electrical busway sections, then electrical connection is achieved, but flexibility and reconfigurability are lost

Engineering Contradiction:

ImproveflexibilityVSAvoidpermanent deformation requirement

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by replacing rigid bus bars with flexible cables that can dynamically adapt to different spatial configurations. The flexible cable assembly allows the electrical busway system to be reconfigured into various orientations without permanent deformation, enabling dynamic adjustment while maintaining electrical connectivity between sections.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent employs flexible cables with insulating coverings (flexible shells) to replace rigid conductors. These flexible cable assemblies can bend and conform to different spatial arrangements while providing reliable electrical connection, thereby achieving flexibility and reconfigurability without the need for permanent deformation of rigid components.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If flexible busway assemblies with termination boxes are used, then flexibility is improved, but device complexity and bulk increase

Engineering Contradiction:

ImproveflexibilityVSAvoidtermination box complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of the flexible cable assembly and the connection interface into a single integrated unit. By eliminating separate termination boxes and directly coupling the flexible cable assembly between busway sections, the design reduces device complexity and bulk while maintaining flexibility. The coupling mechanism is integrated into the flexible assembly itself, consolidating multiple components into one.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and removes the bulky termination boxes from the flexible busway assembly. By eliminating these separate components and their associated multiple termination points, the design reduces device complexity and bulk. The essential flexibility function is retained through the flexible cable assembly alone, without the unnecessary complexity of termination boxes.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If multiple separate terminations are used in termination boxes, then electrical connection is achieved, but stress concentration and susceptibility to damage increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidstress concentration

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent merges multiple separate termination points into a single integrated flexible cable assembly connection. Instead of having multiple independent terminations in separate boxes, the flexible cable assembly provides a unified connection interface that distributes stress more evenly, reducing stress concentration at individual termination points and improving reliability.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If rigid bus bars are used, then structural strength is maintained, but space occupation increases and labor intensity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidspace occupation

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The patent uses flexible cables with insulating coverings instead of rigid bus bars. These flexible cable assemblies have a smaller cross-sectional area and can be routed through tighter spaces, reducing the overall space occupation of the electrical busway system while maintaining the necessary structural strength for electrical connection and mechanical support.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS7614895B2Electrical busway and coupling assembly therefor

Publication Date: 2009.11.10 EATON INTELLIGENT POWER LTD

AI summary

A coupling assembly is provided for an electrical busway having a first section and a second section. The coupling assembly includes at least one housing having first and second ends. A plurality of electrical conductors extend through such housing and electrically connect the first and second sections of the electrical busway. A plurality of electrical insulators surround at least some of the electrical conductors. A first coupling member couples the first end of the at least one housing to the first section of the electrical busway, and a second coupling member couples the second end of such housing to the second section of the electrical busway. The at least one housing and the electrical conductors extending therethrough are flexible, and the housing is electrically grounded. The coupling assembly electrically connects the first and second sections of the electrical busway, without a number of separate termination boxes.