Transverse Cylinder Busbar for Offset Terminal Contact
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Solution Overview
Problem
In the automotive field, existing electrical connection solutions for inverters and electrical machines face challenges in maximizing space efficiency and integration density within compact vehicle housings, particularly in achieving reliable electrical connections between power modules and machine terminals.
Innovation Solution
An electrical connection bar with a conductive cylinder extending transversely from a flat portion, coated with insulating material and featuring protrusions for mechanical retention, allows for operational contact with electrical terminals by offsetting the connection point, enabling efficient energy exchange and improved component integration within the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical connection bar uses a conventional flat design without transverse extensions, then the manufacturing process is simpler, but the integration density within the housing is reduced and reliable contact with offset terminals cannot be achieved
Solution Approach 1:
The connection bar transitions from a conventional two-dimensional flat design to a three-dimensional structure by adding a transverse cylinder extending perpendicular to the main plane. This dimensional extension enables the bar to reach terminals located at offsets from the main mounting plane, establishing reliable electrical contact without compromising structural simplicity.
2Area of stationary object
If the electrical connection bar is designed with a compact layout, then the housing footprint is minimized, but the ability to reach offset terminals is compromised
Solution Approach 1:
By extending the connection bar vertically in the transverse direction (perpendicular to the main plane), the design achieves terminal contact capability without increasing the horizontal footprint. The cylinder portion reaches offset terminals while the base remains compact within the housing plane, resolving the contradiction between compact layout and contact capability.
Solution Approach 2:
The connection bar is segmented into distinct functional portions: a flat base portion for mounting within the housing plane and a transverse cylindrical portion for reaching offset terminals. This segmentation allows each portion to optimize its function while maintaining overall compactness.
3Reliability
If the electrical connection bar uses extensive insulating coating coverage, then electrical insulation is improved, but mechanical retention and operational contact with terminals are compromised
Solution Approach 1:
The insulating coating is applied selectively rather than uniformly across the entire connection bar. The coating covers the flat base portion to provide electrical insulation during mounting, but deliberately excludes the transverse cylindrical portion that contacts the terminal. This local differentiation of coating quality enables both insulation and operational contact functions.
Data Source
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AI summary
The invention relates to an electrical busbar (400) intended for electrically connecting an electrical component, said electrical busbar (400) including: at least one electrically conductive part (410); a coating (420) made of electrically insulating material covering said part (410) at least in a main plane of the busbar (400), the electrically conductive part (410) including: a first end forming an electrical connection terminal; a planar portion extending so as to follow said main plane; and an electrically conductive cylinder (414) which extends away from a first surface of the planar portion in a transverse direction relative to the main plane, the inner wall of the cylinder extending away from an opening located in the planar portion so as to receive a rod in order to rest the distal end (414a) of the cylinder (414) on a terminal of the electrical component.