Flexible Polymeric Busbar Kit for Space-Efficient Transport
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Solution Overview
Problem
Conventional busbar systems are complex and expensive to produce, can only be manufactured in fixed lengths, and require intricate adjustments and reliable electrical contacting during installation, making them difficult to handle and transport.
Innovation Solution
A busbar system kit comprising three planar and flexible sections connected via a flexible element and stiffening elements, allowing for easy assembly and customization of lengths, with sections that can be rolled up for space-efficient storage and transport, using polymeric materials and conductive elements arranged in grooves for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional busbar systems are manufactured with multiple materials and complex structures, then electrical safety and functionality are improved, but production complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple previously separate components (busbar, insulation, mounting elements, electrical contacts) into a single integrated polymeric profile. This merging reduces the number of different materials and parts that need to be combined during production, thereby reducing production complexity while maintaining electrical safety through the integrated design.
Solution Approach 2:
The patent uses a polymeric material that integrates multiple functions (insulation, structure, mounting) into a single composite material system. This composite approach eliminates the need to combine multiple different materials during assembly, reducing production complexity while maintaining the electrical safety properties through the inherent insulating and structural characteristics of the polymer.
2Ease of manufacture
If conventional busbar systems are produced in fixed lengths, then manufacturing simplicity is improved, but adaptability to different installation requirements deteriorates
Solution Approach 1:
The patent introduces flexibility into the busbar system by making the polymeric profile itself flexible rather than rigid. This allows the busbar to be adapted to different lengths and installation configurations without requiring complex joining mechanisms, thereby maintaining manufacturing simplicity while significantly improving adaptability to various installation requirements.
Solution Approach 2:
The patent enables continuous variation of the busbar length parameter by producing the flexible polymeric profile in long continuous lengths that can be cut to any required size. This parameter change approach allows the same manufacturing process to produce busbars of any length, improving adaptability while maintaining manufacturing simplicity.
3Stability of the object's composition
If conventional busbar systems use rigid structures, then structural stability is improved, but ease of transport and storage deteriorates due to space requirements
Solution Approach 1:
The patent employs a flexible polymeric profile that can be bent and rolled into compact forms for transport and storage. The flexibility of the polymer shell allows the busbar to be stored in a rolled-up state occupying minimal space, while the inherent structural design of the profile maintains structural stability when installed and used in its functional configuration.
4Reliability
If conventional busbar systems require intricate adjustments during installation, then precise electrical contacting is improved, but assembly time and effort increase
Solution Approach 1:
The patent incorporates self-aligning and self-adjusting features directly into the polymeric profile structure, such as integrated mounting elements and electrical contacts that automatically position themselves during installation. This self-service design eliminates the need for intricate manual adjustments, thereby maintaining reliable electrical contacting while significantly reducing assembly time and effort.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A kit for a busbar system (1) comprising at least partially polymeric materials, comprising at least three sections (2, 3, 4) extending longitudinally in the busbar system (1), wherein the three sections (2, 3, 4) are connectable to form a hollow body that at least partially encloses a cavity (11) and forms the busbar system (1), wherein the three sections (2) are essentially planar and flexible and can be transformed from a first state (eZ) in which the sections (2, 3, 4) are movable and can be rolled up from a planar or parallel arrangement to a second state (zZ) in which the sections (2) form the busbar system (1), characterized in that at least one section (2, 3, 4) has at least one electrically conductive element arranged longitudinally in a groove (5) in the busbar system (1), and that the sections (2, 3,4) are connected to each other by at least one flexible element (7) and that at least two sections (2) have at least one connecting device (9, 9').