Laser-Joined Segmented Bus Bar for Complex Wiring Paths
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Solution Overview
Problem
The formation of bus bars with complex wiring pathways is costly and prone to cracking due to small bending radii, making it difficult to manufacture and meet requirements for various shapes.
Innovation Solution
A bus bar with a wiring pathway composed of consecutively arranged plate-shaped members of different characteristics, connected by laser joining, which includes connection members for electrical input-output and a conductive member with different materials, thicknesses, and surface treatments, allowing for flexible shaping and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If press working is used to form the member along the wiring pathway, then the member can be formed into complex shapes, but the dies become complicated and manufacturing cost increases
Solution Approach 1:
The bus bar is divided into multiple members (first member, second member, third member) that can be manufactured separately using simple dies and then assembled together. This segmentation allows each member to be formed with simpler tooling while achieving the overall complex wiring pathway shape through the combination of multiple components.
2Shape
If a forming process is used to create the member along the wiring pathway, then the member can be shaped, but it cracks when the bending radius is small
Solution Approach 1:
By dividing the bus bar into multiple members with larger bending radii, each segment can be formed without cracking. The complex wiring pathway shape is achieved by assembling these crack-free segments rather than forming a single member with small bending radii.
Solution Approach 2:
The invention changes the bending radius parameter of each individual member to be larger than the critical value that causes cracking. By adjusting this geometric parameter, the forming process becomes feasible without causing member failure.
3Adaptability or versatility
If a single plate shaped member is used for the wiring pathway, then the structure is simple, but it cannot easily accommodate various wiring pathway shapes
Solution Approach 1:
The bus bar structure is segmented into multiple members that can be independently configured. This allows the assembly to adapt to various wiring pathway shapes by arranging the members differently, while each individual member remains relatively simple in structure.
Solution Approach 2:
The multiple members are designed with universal connection interfaces (laser joining surfaces) that allow them to be assembled in different configurations. This multi-functionality enables the same set of members to accommodate various wiring pathway shapes without requiring completely different structures.
4Adaptability or versatility
If multiple members with different characteristics are laser joined, then various wiring pathway shapes can be achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention replaces traditional mechanical joining methods (such as bolting or riveting) with laser joining. This substitution simplifies the manufacturing process by eliminating the need for complex mechanical fastening operations while enabling the assembly of multiple members with different characteristics into various wiring pathway configurations.
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
Enables the cost-effective production of bus bars that can easily accommodate various wiring pathways without cracking, improving electrical connection reliability and reducing manufacturing costs by using laser joining and tolerance buffers to absorb dimensional tolerances.
Implementation Method 1
The members adjacent to each other are laser joined members
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A bus bar (1) includes a wiring pathway (7) made from a conductive material and having bent portions (5) bending at at least two sites of the wiring pathway (7). The wiring pathway (7) includes members (9) consecutively arranged to form a plate shape. At least two of the members (9) have different characteristics. The members (9) adjacent to each other are connected to each other by laser joining.