Segmented Conductor Coupler for Low-Resistance Busbar Joints
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Solution Overview
Problem
Existing electrical connections between conductors, particularly copper busbars, suffer from inadequate electrical contact due to improper clamping, leading to increased joint resistance and impediments to electrical flow, exacerbated by the ductility of copper which hinders improvements in contact with increased clamp force.
Innovation Solution
A coupler with a clip and fastening system that increases the contact area between conductors by reducing the gap between clip segments, using a bolt and nut mechanism to enhance compression and electrical contact, while incorporating a mating feature to restrict angular movement and prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If clamp force is increased to improve electrical contact, then electrical contact quality improves, but the ductility of copper conductors prevents commensurate improvement in contact
Solution Approach 1:
The clip is divided into multiple segments (first clip segment and second clip segment) that can independently deform and conform to the conductor surfaces. This segmentation allows each segment to adapt to the ductile conductor material, maximizing contact area without requiring excessive clamp force that would deform the copper conductors.
Solution Approach 2:
The clip segments are designed with dynamic flexibility to adjust and conform to the conductor geometry. The segments can deform elastically to match the surface contours of the ductile copper conductors, ensuring optimal electrical contact while accommodating the material's tendency to deform under pressure.
2Reliability
If contact area between conductors is increased to reduce joint resistance, then electrical flow improves, but conventional clamp systems cannot provide sufficient compression
Solution Approach 1:
The clip segments feature curved or contoured surfaces that match the geometry of the conductors, maximizing the contact area. The curved surfaces of the clip segments conform to the conductor shapes, creating larger contact zones that reduce joint resistance and improve electrical flow without requiring proportionally higher compression forces.
Solution Approach 2:
The invention changes the geometric parameters of the contact interface by using shaped clip segments with specific curvature and surface area characteristics. These parameter changes allow the clip to distribute compression force over a larger area, reducing contact pressure while maintaining large contact area for improved electrical flow.
3Ease of manufacture
If conventional clamp systems are used to connect conductors, then connection is achieved, but joint resistance remains relatively large
Solution Approach 1:
The clip segments are designed to copy or replicate the surface geometry of the conductors, creating intimate contact between the clip and conductor surfaces. By conforming to the conductor shape, the clip segments ensure large contact area and low joint resistance while maintaining ease of installation similar to conventional clamp systems.
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
Enhances electrical conductivity and reduces resistance at the joint by increasing the contact area and maintaining stable contact, thereby improving the electrical connection and minimizing creepage.
Implementation Method 1
an actuation of the fastening system reduces a gap between the first clip segment and the second clip segment to increase a compression and contact between the first conductor and the second conductor
Implementation Method 2
The first clip segment and the second clip segment are configured to respectively abut with the first conductor and the second conductor to accommodate overlapped portions of the first conductor and the second conductor therebetween
Data Source
AI summary
A coupler for electrically connecting a first conductor to a second conductor includes a clip and a fastening system. The clip defines a first clip segment and a second clip segment. The segments are configured to respectively abut with the conductors to accommodate overlapped portions of the conductors therebetween. The fastening system is engageable with the segments such that an actuation of the fastening system reduces a gap between the segments to increase a compression and contact between the conductors. Compared to surface areas of the fastening system, the segments define relatively larger corresponding surface areas for respectively contacting the conductors and providing commensurate compression therebetween.