Fused-Wire Cable Connector for Busbar
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable connectors for busbars often experience increased electrical resistance over time due to loosening crimped terminals, leading to insecure and high-resistance connections.
Innovation Solution
A fused-wire cable connector with a trapezoidal cross-section and a connector formed by fusing the ends of wires, which includes an aperture for a fastener to securely couple to a busbar, reducing resistance through alignment and contact with a port that includes ribs to remove oxidation and enhance conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fused-wire connector is used instead of crimped terminals, then connection stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the connector formation and attachment processes into a single fusion operation. The mold simultaneously shapes the connector and fuses it to the busbar, eliminating separate crimping or fastening steps and simplifying the overall manufacturing process despite the thermal processing requirement.
Solution Approach 2:
The fused connector is designed to be self-aligning and self-securing through the fusion process itself. The molten material naturally flows and bonds to the busbar surface, eliminating the need for additional alignment fixtures or fastening operations that would increase manufacturing complexity.
2Strength
If the connector is formed by fusing wire ends, then a secure bond is achieved, but the process requires additional heating and molding steps
Solution Approach 1:
The patent combines shaping and bonding into a single mold operation. The mold cavity defines both the connector geometry and the fusion interface, allowing the wire ends to be shaped and bonded simultaneously in one heating cycle, rather than requiring separate forming and attachment steps.
Solution Approach 2:
The mold is pre-configured with the exact geometry and positioning required for the fusion bond. Wire ends are inserted into pre-positioned mold cavities that ensure proper alignment and contact with the busbar before heating begins, eliminating the need for time-consuming alignment adjustments during the fusion process.
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
The solution provides a secure, low-resistance coupling between the cable and busbar, reducing electrical resistivity and preventing connection loosening by ensuring a stable, conductive interface.
Implementation Method 1
heating the ends, and fusing the ends together by pressing the heated ends into the mold
Implementation Method 2
fusing the ends together by pressing the heated ends into the mold
Data Source
AI summary
Method, systems, and apparatus are disclosed for fused-wire cable connectors for a busbar. An example cable includes wires, insulation around the wires, and a connector extending from the wires beyond the insulation. The example connector is formed from ends of the wires that are fused together. The example connector defines an aperture that is to receive a fastener to couple the connector to a busbar.