Segmented Busbar Structure for Vibration-Tolerant Power Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional busbars in automotive, military, marine, and aviation applications face challenges due to their high manufacturing costs, inability to accommodate manufacturing tolerances, and high failure rates, especially in environments with vibration, heat, and moisture, which limit their performance and reliability.
Innovation Solution
A busbar with integrated fused and unfused segments, where the fused segments provide stiffness for accurate bending and current flow, while the unfused segments offer flexibility to absorb vibrations and expand/contract, reducing the need for custom molds and connectors, and enabling complex geometric configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional custom fabricated busbars are used to achieve complex geometric configurations, then the busbar can be formed with required shapes, but the manufacturing cost increases and installation becomes difficult
Solution Approach 1:
The busbar is divided into multiple segments that can be independently formed and then joined together. This segmentation allows each segment to be manufactured using standard processes rather than requiring custom fabrication of the entire complex geometry, reducing manufacturing costs while achieving the required complex overall shape through assembly of standardized segments
Solution Approach 2:
Multiple busbar segments are nested or joined together to form the complete complex geometric configuration. The segments can be interconnected through standardized connection interfaces, allowing complex shapes to be built from simpler components that are easier and less expensive to manufacture
2Ease of operation
If conventional fasteners are used to couple busbars to power sources and components, then electrical connections can be established, but installation becomes extremely difficult due to protective equipment requirements
Solution Approach 1:
The patent replaces traditional mechanical fastening systems (bolts, nuts, washers) with a push-connect electrical connection system. This substitution eliminates the need for complex protective equipment during installation, as the push-connect mechanism can be safely operated without the same level of protective gear required for conventional electrical fastening, while still establishing reliable electrical connections
3Reliability
If custom fabricated busbars with complex geometries are installed, then power distribution requirements are met, but failure rates increase due to vibration, heat, and moisture
Solution Approach 1:
By segmenting the busbar into modular sections with standardized connections, the system can better accommodate thermal expansion and contraction, reducing stress accumulation that leads to failure in harsh environments. The segmented design allows each section to move independently, reducing the impact of vibration and thermal cycling on the overall structure
Solution Approach 2:
The patent modifies the physical and material parameters of the busbar segments and connections to improve resistance to environmental factors. This includes selecting materials and connection designs that maintain electrical and mechanical integrity under vibration, heat, and moisture exposure, thereby reducing failure rates in challenging operating conditions
4Adaptability or versatility
If conventional busbars are used in power distribution systems, then electrical connections are established, but any alterations require altering busbar configurations which is time-consuming
Solution Approach 1:
The modular segmented design allows individual segments to be easily removed, added, or reconfigured without affecting the entire busbar structure. This segmentation enables quick system alterations by simply disconnecting and reconnecting segments at standardized interfaces, rather than requiring time-consuming custom fabrication and installation
Solution Approach 2:
The standardized connection interfaces and uniform segment designs enable the busbar system to be easily reconfigured for different applications and layouts. The universal segment design can be adapted to various power distribution configurations, allowing rapid system alterations and reconfigurations without custom fabrication
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 solution reduces manufacturing costs, enhances reliability, and improves performance by allowing the busbar to maintain in-plane bends without delamination, absorb environmental stresses, and integrate seamlessly with other components, thus reducing failure rates and installation complexities.
Implementation Method 1
The fused segment of the busbar contains at least one region of conductors that has been partially solidified or fully solidified, which increases the stiffness of the fused segment of the busbar. The unfused segment of the busbar contains unsolidified regions of conductors, not partially solidified or fully solidified regions of conductors, that cause the unfused segment to be flexible
Data Source
AI summary
A busbar for use in mechanically and electrically connecting components in a device or system. The busbar includes a plurality of conductors arranged to provide two opposed end portions and an intermediate portion, wherein each of the conductors has a plurality of intermediate extents that traverse the intermediate portion. The intermediate portion including: (A) an unfused segment where no intermediate extents of the conductors are fused together to form a single consolidated conductor, and (B) a fused segment that includes (i) a partial solidification zone where a majority of the intermediate extents of the conductors are fused together to form a partially solidified region that provides a single consolidated conductor, (ii) a full solidification zone where all of intermediate extents of the conductors are fused together to form a fully solidified region that provides a single consolidated conductor, and (iii) an unsolidified region where all of the intermediate extents of the conductors are not fused together.