V-Shaped Bus Bar System with Segmented Plastic Shells
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Solution Overview
Problem
Traditional bus bar systems are costly, environmentally unfriendly, and difficult to manufacture due to the use of thermosetting plastic and high material consumption, with additional costs from insulating layers and complex processing requirements.
Innovation Solution
A bus bar system featuring a V-shaped configuration with overlapping conductor components sandwiched between upper and lower plastic shells, eliminating the need for external insulating materials and reducing manufacturing complexity, while incorporating arc-shaped middle parts for electrical clearance and heat dissipation protrusions for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermosetting plastic is used to press bus conductors into a solid body for insulation, then insulation between bus conductors is achieved, but weight increases and material consumption increases
Solution Approach 1:
The plastic shell is divided into upper and lower separate parts that sandwich the bus conductors, eliminating the need for a single solid pressed structure. This segmentation reduces material consumption and weight while maintaining insulation through the sandwich configuration.
2Reliability
If thermosetting plastic mould is used to press bus conductors, then insulation is achieved, but material cost increases and environmental friendliness decreases
Solution Approach 1:
Dividing the plastic shell into separable upper and lower parts simplifies the manufacturing process, eliminating complex thermosetting moulding operations. This reduces manufacturing cost and enables easier recycling of materials, improving environmental friendliness.
Solution Approach 2:
The plastic shells function as protective enclosures rather than solid pressed structures, using thinner material layers to achieve the same insulation effect. This reduces material cost and improves manufacturability.
3Reliability
If insulating layers are attached on the outer surface of each phase bus conductor, then insulation among bus conductors is achieved, but cost increases due to additional materials and labor
Solution Approach 1:
The insulation function is merged into the plastic shell structure itself rather than being a separate layer attached to conductors. The upper and lower plastic shells together provide the insulation barrier, eliminating the need for additional insulating layers on conductor surfaces.
Solution Approach 2:
The insulation function is extracted from the conductor surface treatment and transferred to the enclosing plastic shell structure. This eliminates the need for heat-shrinkable tubes or other surface insulating layers, reducing both material and labor costs.
4Reliability
If four different kinds of bus conductors are processed, then specific electrical requirements are met, but inventory cost increases and manufacturing complexity increases
Solution Approach 1:
The plastic shell structure serves multiple functions simultaneously: it provides mechanical support, electrical insulation, and protective enclosure for all bus conductor types. This universal design allows the same shell structure to accommodate different conductor configurations without requiring specialized processing for each type.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
This application provides a bus bar system, including: an upper plastic shell (3); a lower plastic shell (4); a first bus conductor assembly (1); a second bus conductor assembly (2); wherein, the first bus conductor assembly (1) and the second bus conductor assembly (2) comprise a plurality of conductor components respectively, a V-shaped bus bar assembly is formed by the corresponding conductor components of the first bus conductor assembly (1) and the second bus conductor assembly (2)by overlapping; and the two bus conductor assemblies (1, 2) are sandwiched and fixed between the upper plastic shell (3) and the lower plastic shell (4).