Interdigitated Joint for Electrical Interconnects
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Solution Overview
Problem
Conventional power distribution systems experience increased resistance and heat generation due to component misalignment and tolerance stack-ups, necessitating improved interconnect arrangements for conductive components in electrical assemblies like power distribution panels.
Innovation Solution
An electrical interconnect arrangement featuring an interdigitated joint with multiple interfaces between a bus bar and a post, where the bus bar and post can be angled and have interleaved terminations and prongs, reducing heat transfer and resistive heating through the use of multiple conductive interfaces and a fastener for compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional single-interface joints are used to connect bus bar with post, then device complexity is reduced, but resistive heating and joint loss increase significantly
Solution Approach 1:
The joint structure is segmented into multiple interfaces (first interface, second interface, third interface) by dividing the bus bar into multiple terminations and the post into multiple prongs. This segmentation distributes the current flow across multiple contact points, reducing the current density and resistive heating at each individual interface while maintaining overall electrical connectivity.
Solution Approach 2:
The joint structure transitions from a single-plane interface to a multi-dimensional interdigitated arrangement. The terminations and prongs are positioned at different spatial locations and angles, creating a three-dimensional current distribution pattern that reduces concentration of heat and improves thermal management.
2Temperature
If multiple interfaces are introduced in the joint to reduce heat transfer, then resistive heating decreases, but manufacturing precision requirements increase
Solution Approach 1:
The terminations and prongs are arranged in a nested or interdigitated pattern where components are positioned in alternating sequences. This nesting arrangement provides inherent alignment guidance and tolerance compensation, as each interface can be independently positioned while maintaining overall structural integrity through the fastener.
Solution Approach 2:
The joint structure allows for parameter variations in interface positioning, angles, and spacing. The fastener provides compression force that compensates for manufacturing tolerances, ensuring reliable electrical contact across all interfaces even with variations in assembly parameters.
3Object-affected harmful factors
If interdigitated joint with multiple interfaces is used, then heat transfer into post is limited, but device complexity increases
Solution Approach 1:
The harmful heat transfer path is extracted and interrupted by introducing multiple interfaces with air gaps or insulating barriers between them. The fastener applies compression to ensure electrical contact while the multi-interface design inherently limits thermal conduction paths from the bus bar to the post, protecting the post from excessive heat.
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 configuration significantly reduces resistive heat generation by minimizing joint loss, achieving a 62.5% to 77.7% reduction in joint loss compared to single-interface joints, thereby lowering contactor temperatures and enhancing heat removal capabilities.
Implementation Method 1
Current flows between the power source and the load in the on state, typically generating heat by resistive heating of current-carrying components connecting the load with the power source
Implementation Method 2
The heat generated by a current-carrying component generally corresponds with its resistance
Data Source
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AI summary
An electrical interconnect arrangement for coupling a contactor with a bus bar includes a post, a bus bar connected electrically to the post, and a joint coupling the bus bar to the post. The joint has two or more interfaces defined between the post and the bus bar to reduce resistive heat generation within the electrical interconnect arrangement.