Resilient Bus Bar with Lateral Recesses for Thermal Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing bus bar designs in vehicles, made of rigid conductive metal and non-conductive plastic, experience thermal expansion mismatch, leading to shear forces that can break the fuse due to differing thermal expansion coefficients, causing functionality loss in extreme temperatures.
Innovation Solution
A straight bus bar with a resilient compensation portion featuring lateral recesses that allow elastic bending, connecting rigid portions to accommodate axial movement and prevent shear forces on the fuse, ensuring the fuse remains intact across temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid bus bar made of metal is used to ensure mechanical strength and electrical conductivity, then the structural integrity is improved, but the thermal expansion mismatch with plastic housing causes shear forces that can break the fuse
Solution Approach 1:
The bus bar is segmented into a rigid portion and a resilient compensation portion. The rigid portion maintains mechanical strength and electrical conductivity, while the resilient compensation portion with lateral recesses allows thermal expansion and contraction, preventing shear forces on the fuse.
Solution Approach 2:
The bus bar's structural parameters are changed by introducing lateral recesses in the connecting portion, transforming it from a completely rigid structure to one with controlled flexibility. This allows the bus bar to accommodate thermal expansion differences between metal and plastic materials.
2Reliability
If the bus bar is made completely rigid to maintain electrical connectivity, then the electrical conductivity is improved, but the bus bar cannot accommodate thermal expansion differences, causing stress on connected components
Solution Approach 1:
The bus bar is divided into rigid portions for electrical connectivity and a resilient compensation portion with lateral recesses that accommodates thermal expansion. This segmentation allows each portion to fulfill its specific function without compromising the other.
Solution Approach 2:
The resilient compensation portion is specifically designed to accommodate thermal expansion and contraction of the bus bar. The lateral recesses allow the material to expand into these spaces during temperature changes, preventing stress buildup and potential damage to connected components.
3Adaptability or versatility
If lateral recesses are added to the connecting portion to enable elastic bending, then the ability to accommodate thermal expansion is improved, but the manufacturing complexity increases
Solution Approach 1:
Lateral recesses are introduced only in the connecting portion of the bus bar where thermal compensation is needed, while the rigid portions remain unchanged. This localized modification provides thermal adaptability where required without unnecessarily complicating the entire manufacturing process.
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
The bus bar effectively prevents fuse breakage by allowing relative axial movement between the bus bar and housing, maintaining electrical connectivity and vehicle functionality across varying temperatures.
Implementation Method 1
The connecting portion is a resilient compensation portion having at least two lateral recesses extending from opposite sides into the bus bar making the connecting portion elastically bendable to allow a relative axial movement of the first and second portions when an axial force is applied to the bus bar
Implementation Method 2
When the vehicle is exposed to hot or cold climate conditions, the bus bar and the housing will thermally expand or contract due to a change of temperature. A problem occurs due to the fact that the bus bar made of metal and the housing made of plastic have different thermal expansion coefficients.
Data Source
AI summary
A straight bus bar includes an axial direction and having a rigid first portion with a first contact surface connectable to a first fuse, an axially spaced rigid second portion with a second contact surface connectable to a second fuse, and a connecting portion electrically connecting the first portion and the second portion. The connecting portion is a resilient compensation portion having at least two lateral recesses extending from opposite sides into the bus bar making the connecting portion elastically bendable to allow a relative axial movement of the first and second portions when an axial force is applied to the bus bar.