Two-Piece HV Terminal Frame for Integrated Bus Bar Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high voltage terminal frames require separate components for the rigid outer housing and compliant contact spring, necessitating assembly and potentially leading to a three-piece assembly with crimping of the bus bar, which is cumbersome.
Innovation Solution
A two-piece high voltage terminal frame design where the terminal frame and contact spring are fabricated from different thicknesses of the same material, with the terminal frame providing rigidity and the contact spring being more flexible, eliminating the need for separate components and crimping by integrating the bus bar directly into the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components are used for rigid outer housing and compliant contact spring, then structural integrity and functionality are achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the rigid outer housing and compliant contact spring into a single integrated terminal frame component. The terminal frame is designed with varying thickness to provide both rigid structural support and compliant contact areas, eliminating the need for separate components and simplifying assembly while maintaining structural integrity and functionality.
2Reliability
If a conductive bus bar is crimped to the rigid outer housing, then electrical connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The bus bar is integrated directly into the terminal frame by forming it as an extension of the terminal frame itself, eliminating the need for separate crimping operations. This integration maintains reliable electrical connection while significantly simplifying the manufacturing process.
3Reliability
If different materials are used for terminal frame and contact spring, then optimal mechanical properties are achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The terminal frame is designed with varying thickness to provide different mechanical properties in different areas. Thicker sections provide rigid structural support while thinner sections provide compliant contact areas, all made from the same material. This eliminates the need for multiple materials while achieving optimal mechanical properties through geometric design.
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
This design simplifies assembly, enhances rigidity and flexibility, and allows for bi-directional bus bar connection, improving the overall functionality and ease of manufacturing while reducing component count.
Implementation Method 1
the contact spring includes a spring portion that extends into the opening of the terminal frame
Data Source
AI summary
A two-piece high voltage (HV) terminal frame having a terminal frame and a contact spring. The terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar. The contact spring is configured to engage the top portion of the terminal frame, wherein the contact spring includes a spring portion that extends into the opening of the terminal frame.