Stacked Busbar Connector for Confined Space Integration
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Solution Overview
Problem
Existing busbar connectors and busbars often fail to efficiently fit within confined spaces due to their side-by-side arrangement, making them unsuitable for certain components with limited chassis space.
Innovation Solution
A reconfigured busbar assembly with vertically stacked contact tabs and electrical contacts, allowing for a connector assembly with aligned interfacing spaces that can mate in a vertically stacked orientation, enabling the system to fit into smaller spaces and accommodate different orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If busbar connectors use a side-by-side arrangement of electrical contacts, then the connector can accommodate traditional orthogonal connectors, but the connector cannot fit within confined spaces of certain components
Solution Approach 1:
The patent transitions from a traditional side-by-side (2D planar) arrangement of electrical contacts to a vertically stacked (3D layered) configuration. This dimensional change allows the connector to reduce its footprint in the horizontal plane while maintaining electrical contact functionality, enabling it to fit within confined spaces of components like power supply units.
Solution Approach 2:
The busbar connector design nests multiple electrical contacts (first and second contacts) vertically within a compact housing structure. The first contact is positioned above the second contact in the vertical direction, creating a nested arrangement that maximizes space utilization and reduces the overall connector volume.
2Ease of manufacture
If busbar connectors use a side-by-side arrangement, then the electrical contacts can be easily manufactured, but the connector assembly becomes too large for certain chassis configurations
Solution Approach 1:
The patent reconfigures the manufacturing layout from a horizontal side-by-side contact arrangement to a vertical stacking configuration. This allows the connector to maintain manufacturing simplicity while reducing the horizontal area occupied in the chassis, enabling integration into compact power supply designs.
Solution Approach 2:
The connector is segmented into distinct vertical layers with the first electrical contact positioned above the second electrical contact. This segmentation allows each contact to be independently manufactured and positioned, maintaining ease of manufacture while achieving a compact vertical arrangement that reduces chassis space requirements.
Data Source
AI summary
An electrical system may include a busbar assembly and a connector assembly. The busbar assembly may include first and second busbars. A first contact tab extends from the first busbar. A second contact tab extends from the second busbar. The first and second contact tabs include first and second interface ends, respectively, within a common plane. The connector assembly includes a housing that retains first and second electrical contacts. The first electrical contact includes a first contact terminal and the second electrical contact includes a second contact terminal. The first contact terminal defines a first interfacing space and the second contact terminal defines a second interfacing space. The first and second interfacing spaces are aligned with one another. The first and second interface ends are configured to mate with the first and second contact terminals within the first and second interfacing spaces, respectively.