Plastic Window Bus Bar Fixing for Thermal Stress
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Solution Overview
Problem
The transition from glass to plastic windows in industrial applications faces challenges due to increased thermal expansion and contraction, leading to stress on bus bars and poor attachment, which affects electric current flow and increases manufacturing costs.
Innovation Solution
A plastic window design featuring a conductive metal strip second bus bar with additional fixing portions and shanks to secure it to the window body, reducing stress and ensuring reliable electrical connection without the need for excessive densification of first bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic window body is used instead of glass, then weight is reduced and manufacturing is simplified, but thermal expansion and contraction increase causing stress on bus bars and poor attachment
Solution Approach 1:
The second bus bar is divided into a main body and multiple fixing portions (at least two) that are separately formed and positioned at different locations. This segmentation allows the fixing portions to be distributed across different expansion zones, reducing the impact of thermal stress on any single attachment point and preventing detachment.
Solution Approach 2:
The fixing portions are designed with specific local characteristics including extended length beyond the main body, larger cross-sectional area than the main body, and positioning that extends along the second surface. These local quality enhancements create stronger attachment points that can withstand the thermal expansion and contraction forces specific to the plastic window body.
2Reliability
If the first bus bar is made with rough surface for conductivity, then electrical connection is achieved, but attachment of fixing portions becomes insufficient
Solution Approach 1:
The fixing portions are designed with locally enhanced properties including extended length and larger cross-sectional area compared to the main body. This local quality enhancement compensates for the rough surface of the first bus bar by providing greater contact area and mechanical engagement, ensuring sufficient attachment strength while maintaining electrical conductivity through the rough surface interface.
Solution Approach 2:
The fixing portions are pre-formed as integral parts of the second bus bar with optimized geometry (extended length, larger cross-section) before assembly. This preliminary action ensures that the attachment components are already prepared with the necessary mechanical strength to overcome the rough surface challenge, eliminating the need for additional processing or adjustment during assembly.
3Device complexity
If electric current flows only through the first bus bar without the second bus bar, then the configuration is simplified, but the first bus bar must be densified or thickened increasing manufacturing cost
Solution Approach 1:
The electrical conduction path is segmented between the first bus bar and the second bus bar. The second bus bar with its fixing portions handles the electrical connection to the conductive portion, while the first bus bar provides additional electrical connection. This segmentation allows both bus bars to have optimized, thinner designs without requiring excessive densification of the first bus bar, reducing material costs while maintaining electrical performance.
Solution Approach 2:
The second bus bar acts as an intermediary element that facilitates electrical current flow from the power source to the conductive portion. By introducing this intermediate conductor with optimized geometry, the system achieves efficient electrical connection without requiring the first bus bar to be overly dense or thick, thereby simplifying manufacturing and reducing costs.
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 enhances durability, reduces weight, simplifies manufacturing, and lowers costs by maintaining reliable electrical connectivity and preventing overheating, while accommodating thermal expansion without compromising attachment.
Implementation Method 1
The conductive portion is energized by electric current flowing from the second bus bar through the first bus bar, thereby producing heat to defog and defrost on the window body.
Implementation Method 2
the plastic window body expands and contracts more due to a change of temperature than the metallic second bus bar
Data Source
AI summary
A plastic window includes a plastic window body, a conductive portion, a first bus bar, and a second bus bar. The window body is formed in a plate shape and has a first surface and a second surface on both sides thereof. The conductive portion and the first bus bar are made of a conductive material and disposed on the second surface of the window body. The first bus bar is electrically connected to the conductive portion. The second bus bar is made of a conductive metal strip and disposed to be electrically connected to the first bus bar. The second bus bar has a main body, first fixing portions, and second fixing portions. The first fixing portions fix the main body to the second surface. The second fixing portions extend from the main body along the second surface and are attached to the first bus bar.