Integrated Power Bus Bar for Aircraft Distribution
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Solution Overview
Problem
Existing power distribution systems in aircraft face challenges in efficiently integrating power and signaling, leading to complex and bulky designs with increased weight and vulnerability to component failures.
Innovation Solution
A modular power distribution assembly featuring a bus bar with a conductive core covered by a dielectric layer and conductive traces, allowing for simultaneous power and signaling transmission through power cuts and traces, connected to printed circuit boards (PCBs) for controlled power distribution and switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bus bars are used for power and signaling, then reliability is improved by isolating power transmission from signaling, but device complexity increases and weight increases due to multiple separate components
Solution Approach 1:
The patent combines power transmission and signaling functions into a single integrated bus bar structure. The bus bar includes a power transmission path and a signaling path formed on the same substrate, eliminating the need for separate bus bars. This integration reduces the number of components while maintaining functional isolation through the substrate structure, thereby reducing device complexity without compromising reliability.
Solution Approach 2:
The bus bar is designed to perform multiple functions simultaneously: it transmits power through the conductive path and carries signaling through the signaling path formed on the substrate. This multi-functional design allows a single component to replace what would traditionally require separate dedicated components for each function, reducing overall system complexity.
2Reliability
If separate bus bars are used for power and signaling, then reliability is improved by isolating power transmission from signaling, but weight increases due to multiple separate components
Solution Approach 1:
The patent combines power transmission and signaling functions into a single integrated bus bar structure. The bus bar includes a power transmission path and a signaling path formed on the same substrate, eliminating the need for separate bus bars. This integration reduces the number of components and associated mounting hardware, thereby reducing overall weight while maintaining functional isolation through the substrate structure.
3Reliability
If separate bus bars are used for power and signaling, then reliability is improved by isolating power transmission from signaling, but the physical space required increases due to multiple separate components
Solution Approach 1:
The patent combines power transmission and signaling functions into a single integrated bus bar structure. The bus bar includes a power transmission path and a signaling path formed on the same substrate, eliminating the need for separate bus bars. This integration consolidates the physical footprint required for both functions into a single component, reducing the overall area occupied while maintaining functional isolation through the substrate structure.
4Device complexity
If power and signaling are integrated on a single bus bar, then device complexity is reduced and weight is reduced, but the vulnerability to component failures increases
Solution Approach 1:
The patent segments the bus bar into distinct functional paths: a power transmission path and a signaling path. These paths are formed separately on the substrate and remain electrically isolated despite being part of the same physical component. This segmentation allows independent failure modes for each path, so a failure in the signaling path does not affect power transmission and vice versa, thereby maintaining reliability while achieving integration.
Solution Approach 2:
The patent applies different properties to different regions of the bus bar substrate. The substrate is configured to provide electrical isolation between the power path and signaling path in specific local regions, while allowing both paths to coexist in the same overall structure. This local differentiation of properties enables functional isolation within an integrated structure, maintaining reliability without the complexity of separate components.
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 solution reduces weight, simplifies connections, saves space, enhances robustness, and provides scalability and flexibility by integrating power and signaling on a single bus bar, reducing the impact of component failures and improving design integrity.
Implementation Method 1
a dielectric layer on an exterior surface of the conductive core
Implementation Method 2
A power bus extends from the PCB, and has a conductive core, a dielectric layer on an exterior surface of the conductive core, a second conductive trace on the dielectric layer
Data Source
AI summary
A power distribution assembly includes a printed circuit board (PCB) having a power input and electrical components connected to PCB conductive trace. A power bus extends from the PCB and has a conductive core, a dielectric layer on an exterior surface of the conductive core, a conductive trace on the dielectric layer, and a power cut through the dielectric layer to the conductive core. The conductive core is connected to the power input by way of the power cut through and the at least one second conductive trace is connected to the PCB conductive trace.