Flexible Electrical Connector for Electrolytic Cells

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Solution Overview

Problem

Conventional flexible electrical connectors in aluminum electrolytic cells limit the internal production area due to their depth dimension, which constrains the productivity and capital costs per tonne of production capacity, as they restrict the reduction of spacing between collector bars and bus bars, leading to increased electrical contact resistance and limited flexibility.

Innovation Solution

A flexible electrical connector assembly with a reduced depth dimension, featuring conductive metal sheets with angled or wedge-shaped connector blocks and slits, allowing for a change in current-carrying direction by more than 90 degrees and offset connections to minimize depth while maintaining flexibility and reducing contact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If conventional flexible electrical connectors are used, then electrical connection is provided between bus bar and collector bar, but the depth dimension of the connector limits the internal production area and increases spacing between components

Engineering Contradiction:

Improveinternal production areaVSAvoiddepth dimension of connector

Core Design Contradiction:

Area of stationary objectVSLength of moving object

Solution Approach 1:

The flexible electrical connector is designed with a bent configuration that changes the current-carrying direction by more than 90 degrees. This dimensional reorientation allows the connector to achieve the necessary electrical connection while reducing its projected depth dimension, thereby increasing the internal production area available within the cell footprint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The connector incorporates a flexible element that can accommodate relative movements between the bus bar and collector bar. This dynamic capability allows the connector to maintain electrical connection while adapting to positional changes, enabling tighter spacing between components without compromising connection reliability.

Inventive Principle:

Principle #15Dynamics

2Area of stationary object

If spacing between collector bars and bus bars is reduced, then internal production area increases, but electrical contact resistance increases with conventional connectors

Engineering Contradiction:

Improveinternal production areaVSAvoidelectrical contact resistance

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The connector design changes the geometric parameters of the electrical path by implementing a bent configuration with specific bend radii and angles. This parameter optimization allows the connector to maintain low electrical contact resistance even when the spacing between collector bars and bus bars is reduced, as the current path is efficiently routed through the bent structure.

Inventive Principle:

Principle #35Parameter changes

3Area of stationary object

If connector depth is reduced, then internal production area increases, but flexibility to accommodate relative movements is limited

Engineering Contradiction:

Improveinternal production areaVSAvoidflexibility to accommodate relative movements

Core Design Contradiction:

Area of stationary objectVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If conventional connector design is used, then electrical connection is provided, but capital costs per tonne of production capacity increase

Engineering Contradiction:

Improveelectrical connectionVSAvoidcapital costs per tonne of production capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The connector design integrates multiple functions into a single component: electrical conduction, mechanical flexibility to accommodate relative movements, and spatial optimization to reduce depth dimension. This multi-functionality eliminates the need for additional components or complex arrangements, thereby reducing capital costs per tonne of production capacity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10855040B2Flexible electrical connectors for electrolytic cells

Publication Date: 2020.12.01 HATCH LTD

AI summary

A flexible electrical connector assembly is adapted to connect a bus bar of an electrolytic cell to a collector bar of the electrolytic cell. The assembly includes an electrical connector including a plurality of conductive metal sheets, the electrical connector having a collector bar end and a bus bar end. The electrical connector may be adapted for being joined, at the collector bar end, to the collector bar and, at the bus bar end, to the bus bar. The electrical connector may be adapted to implement a change in direction, at a bend along a current-carrying path between the bus bar end and the collector bar end, the bend assisting to define the change in direction as greater than 90 degrees.