Shielded Busbar Structure for Magnetic Field Mitigation
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Solution Overview
Problem
Existing busbar systems face challenges in effectively mitigating magnetic fields, particularly in environments with sensitive electronic equipment, as conventional shielding solutions are either ineffective or complex to implement, and often result in increased temperatures and manufacturing complications.
Innovation Solution
A busbar design featuring a magnetic shielding structure composed of two U-shaped ferromagnetic shielding elements with superimposed fins, made of anisotropic ferromagnetic material, which minimizes air gap reluctance and enhances shielding effectiveness, allowing for easy assembly and integration without visible external shielding, while facilitating heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional outer shielding is wound on the casing, then magnetic field mitigation is achieved, but temperature increases and assembly complexity increases
Solution Approach 1:
The patent introduces an intermediary ferromagnetic layer between the conductor bars and the outer casing. This intermediate layer acts as a magnetic shield that redirects magnetic field lines through itself, preventing them from reaching the outer casing and dissipating heat more effectively. The ferromagnetic material provides a low-reluctance path for magnetic flux, reducing the harmful magnetic field outside while maintaining thermal performance.
Solution Approach 2:
The patent replaces the conventional mechanical winding of outer shielding with a integrated ferromagnetic layer that is part of the busbar structure itself. This substitution eliminates the need for separate shielding components and their associated assembly complexity, while the ferromagnetic material's inherent properties provide both magnetic shielding and thermal management functions.
2Object-affected harmful factors
If conventional outer shielding is wound on the casing, then magnetic field mitigation is achieved, but assembly complexity increases
Solution Approach 1:
The patent merges the magnetic shielding function with the structural body of the busbar by integrating the ferromagnetic layer directly into the casing or support structure. This consolidation eliminates separate shielding components and simplifies assembly, as the shielding function is inherent to the busbar construction rather than an add-on component requiring specialized installation.
Solution Approach 2:
The ferromagnetic layer serves multiple functions simultaneously: it provides magnetic field mitigation, structural support, and thermal management. This multi-functionality reduces the number of separate components needed, simplifying both the design and assembly process while achieving effective magnetic shielding without requiring specialized technicians or complex adaptation work.
3Object-affected harmful factors
If ferromagnetic shielding elements with superimposed fins are used, then magnetic shielding effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the ferromagnetic shielding into discrete elements with fins that can be separately manufactured and then assembled. Each ferromagnetic element can be produced using standard fabrication processes, and the segmented design allows for modular assembly. The fins are positioned to create overlapping configurations that enhance magnetic shielding effectiveness while maintaining manufacturability through standardized components.
Solution Approach 2:
The patent employs a nested arrangement where ferromagnetic elements with fins are positioned within the busbar structure, with fins of one element superimposed on fins of adjacent elements. This nesting creates a layered magnetic shielding effect that enhances performance. The modular nested design allows each component to be manufactured independently using conventional processes, reducing overall manufacturing complexity despite the sophisticated shielding effect.
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 provides improved magnetic shielding, reducing magnetic induction levels, maintaining modularity, and reducing temperature through efficient heat exchange, making it suitable for high-current applications without compromising installation simplicity or aesthetics.
Implementation Method 1
the magnetic shielding structure, arranged between the conductor bars and the outer casing, consists of a first shielding element and a second shielding element, each of which is formed by at least one U-shaped folded strip comprising two fins and a base, made of ferromagnetic material
Implementation Method 2
which also serves the function of thermal dissipation of the heat produced due to the Joule effect by such conductor bars
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Busbar (1) comprising a magnetic shielding structure arranged between the conductor bars (5) and the outer casing (2). The magnetic shielding structure comprises a first shielding element (7) and a second shielding element (8) each having a U-shaped cross- section. The shielding elements (7, 8) are made of ferromagnetic material and enclose - on opposite sides - conductor bars (5) so that each fin (7b, 7c) of the first shielding element (7) is at least partially superimposed on the homologous fin (8b, 8c) of the second shielding element (8). The shielding elements (7, 8) can consist of anisotropic ferromagnetic strips with oriented grains.