Polymer Busbar Spacer With Integrated Latching Mechanism
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Solution Overview
Problem
Existing busbar systems are exposed to weather-related stress, leading to corrosion, and have complex assembly processes requiring additional tools and materials, resulting in increased manufacturing costs and maintenance difficulties.
Innovation Solution
A busbar system with a spacer formed by two carrier elements connected via a traverse, featuring a latching element that connects to a clamping element of a cover element, allowing for tool-free assembly and protection of the current collection surface without additional fastening elements, using polymer materials for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional fastening elements such as screws, brackets, and connecting elements are used to assemble the busbar system, then the structural strength and stability are improved, but the assembly effort, manufacturing cost, and device complexity significantly increase
Solution Approach 1:
The patent combines the spacer function and the fastening function into a single integrated plastic spacer component. The spacer includes built-in latching elements that directly engage with the busbar, eliminating the need for separate screws, brackets, or connecting elements. This merging of functions reduces assembly complexity while maintaining structural strength through the integrated design.
Solution Approach 2:
The spacer is designed with self-latching capability through integrated latching elements that automatically engage with the busbar during assembly. The plastic material and geometric design enable the spacer to secure itself to the busbar without requiring additional fastening operations or tools, making the assembly process self-service and tool-free.
2Strength
If metallic connecting elements are used for assembly, then the mechanical strength is improved, but electrical insulation and protection against accidental contact are compromised
Solution Approach 1:
The patent uses a plastic (polymer) material for the spacer that combines mechanical strength with electrical insulation properties. The plastic material serves as both the structural component and the electrical insulator, eliminating the need for metallic connecting elements. This composite approach maintains mechanical strength while providing inherent electrical insulation and protection against accidental contact.
3Object-affected harmful factors
If complex cover systems with multiple components are used to protect the busbar, then the protection against weather and unauthorized access is improved, but the assembly time and manufacturing cost increase
Solution Approach 1:
The patent integrates the protective cover function directly into the spacer design. The spacer itself forms a protective enclosure around the busbar, and the latching elements are built into this protective structure. This merging of the protective function with the spacing and fastening functions eliminates the need for separate cover components, reducing assembly time while maintaining protection against weather and unauthorized access.
4Ease of manufacture
If traditional busbar systems without integrated spacers are used, then the manufacturing simplicity is maintained, but the assembly requires additional tools and materials leading to increased costs
Solution Approach 1:
The patent segments the busbar system into modular components: the busbar itself and the integrated plastic spacer as a separate assembly unit. The spacer is manufactured as a pre-assembled module with built-in latching elements, allowing it to be produced independently and then quickly installed on the busbar. This segmentation enables simple manufacturing of individual components while achieving high assembly efficiency through modular installation without additional tools or materials.
Data Source
Figure 1
Figure 2
AI summary
The spacer (3) has locking elements (31, 32) connecting with clamping elements (21, 22) of a cover (2) in operative connection. A current collection surface (10) of a busbar (1) is opaquely spaced and arranged at free ends (6) of support elements (7, 8). A distance of the free ends of the support elements from the current collection area corresponds approximately to height of the busbar. A support part (4) is arranged orthogonal to another support part of the free ends of the support elements.