Hinged Modular Power Bar for Vehicle Ground Return
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Solution Overview
Problem
Rigid power bus bars in vehicles pose challenges during shipping, handling, and installation, and the increasing use of non-conducting composite materials in vehicle shells leads to loss of ground return, necessitating a second solid core for grounding.
Innovation Solution
A hinged low profile modular electrical power bar with insulated joints that separate mechanical and electrical connections using different diameter concentric pivots, allowing for rotation and secure mounting while maintaining electrical conductivity, and featuring a connector with sockets and pins for flexible installation and grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid solid core power bar is used, then electrical conductivity is maintained, but handling and installation become difficult
Solution Approach 1:
The power bar is divided into multiple modular segments that can be easily handled and installed individually, then connected together to form the complete power distribution system. Each segment contains its own electrical connections, maintaining conductivity while improving ease of installation.
Solution Approach 2:
The power bar segments incorporate hinged joints with rotational capability, allowing the structure to flex and adapt during installation and vehicle operation. This dynamic design maintains electrical contact while enabling easier handling compared to rigid structures.
2Strength
If vehicle shells are made of non-conducting composite materials, then vehicle structure is improved, but ground return is lost
Solution Approach 1:
A dedicated ground return busbar serves as an intermediary conductive path between the non-conducting composite vehicle shell and the electrical systems. This separate ground return structure compensates for the lack of conductivity in composite materials while maintaining structural integrity.
3Reliability
If a second solid core is added for grounding, then ground return is restored, but device complexity increases
Solution Approach 1:
The ground return function is merged with the power distribution busbar structure itself, rather than being a completely separate system. The busbar segments provide both power distribution and ground return paths through their design, reducing overall system complexity despite the need for dedicated grounding in composite vehicles.
Data Source
AI summary
Systems and apparatus are disclosed for a hinged low profile modular electrical power bar of a vehicle. An example disclosed vehicle power bar includes a connector including first and second sockets. The vehicle power bar also includes first and second pins. Additionally, the vehicle power bar includes a first busbar rotatably coupled to the connector via the first pin coupled to a first terminal of the first busbar and inserted into the first socket, and a second busbar rotatably coupled to the connector via the second pin coupled to a second terminal of the second busbar and inserted into the second socket.