Terminal Assembly Direct Busbar Connection
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Solution Overview
Problem
The existing terminal lug connections to buss bars in electrical systems introduce additional impedance due to intermediate interfaces, which can lead to corrosion, loose connections, and system performance degradation, and require extra assembly steps with coupling screws.
Innovation Solution
A terminal assembly with a mounting base, a buss bar having slots and a slotted extension, and a terminal lug that couples directly to the buss bar without intermediate interfaces, using a fastener to secure the conductor to the slotted extension and a lug clearance recess to prevent sliding, eliminating the need for additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal lug is bolted to the buss bar by an intermediate lug, then the connection is mechanically secure, but additional impedance is introduced due to the extra interface
Solution Approach 1:
The patent removes the intermediate lug component from the connection assembly, creating a direct connection between the terminal lug and buss bar. This extraction of the intermediate element eliminates the additional interface that causes impedance while maintaining mechanical security through the integrated slot and fastener design.
2Strength
If an intermediate lug is used to connect the terminal lug to the buss bar, then mechanical support is provided, but the interface becomes subject to corrosion and impurities that increase impedance
Solution Approach 1:
The intermediate lug is completely removed from the design, eliminating the interface that is susceptible to corrosion and impurities. The direct connection between terminal lug and buss bar reduces the number of potential failure points while maintaining necessary mechanical support through the slot-based retention system.
3Reliability
If a coupling screw is used to secure the lug component to the bus conductor, then the connection is mechanically stable, but extra assembly time and steps are required
Solution Approach 1:
The patent combines the mechanical retention function and electrical connection function into a single integrated structure. The terminal lug with its slot and fastener system performs both retention and electrical connection in one component assembly, eliminating the need for separate coupling screws and reducing assembly steps.
Solution Approach 2:
The terminal lug is pre-configured with the slot and fastener mechanism during manufacturing, so that during assembly only a single fastening operation is needed. The preliminary preparation of the retention features eliminates the need for multiple separate fastening operations that would otherwise be required.
Data Source
AI summary
The present disclosure provides a mounting base, a buss bar with slots and a slotted extension therebetween, and a terminal lug coupled to the buss bar, the terminal lug being adapted to couple directly a conductor to the buss bar at the slotted extension without intermediate interfaces between the conductor and the buss bar. The terminal lug includes a bottom dimensioned to fit on the underside of the slotted extension, and sides dimensioned to fit inside the slots. The terminal lug is restrained from sliding off the slotted extension by being disposed in a lug clearance recess formed in the mounting base that is at a lower elevation than a buss bar support surface. Thus, the system and method provides a direct connection between the conductor and the buss bar, while retaining the terminal lug to the buss bar before the terminal lug is tightened to the buss bar.