Variable-Thickness Busbar Structure for Current Density Optimization
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Solution Overview
Problem
Existing bus bar elements do not consider current density, leading to inefficient material usage and increased volume, which in turn increases production costs and environmental impact.
Innovation Solution
A bus bar element design with varying thicknesses and sloped surfaces to optimize material usage based on current density, allowing for reduced volume and material recycling opportunities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If uniform thickness is used throughout the bus bar element, then manufacturing is simple, but material usage is inefficient and volume is excessive
Solution Approach 1:
The bus bar element employs varying thickness throughout its structure, with thicker sections positioned at terminal bodies and connection points where current density is highest, and thinner sections in areas with lower current density. This local quality variation optimizes material usage by concentrating material where it is most needed for electrical performance while reducing material in less critical areas.
Solution Approach 2:
The invention changes the geometric parameter of thickness from a uniform value to a variable value that changes along the length of the bus bar element. This parameter change allows the structure to adapt to varying current density requirements, improving material efficiency while maintaining electrical performance.
2Quantity of substance
If excessive volume is used in bus bar element, then mechanical strength is sufficient, but production cost increases and environmental impact worsens
Solution Approach 1:
The bus bar element uses non-uniform thickness distribution to concentrate material volume in regions requiring higher mechanical and electrical performance (terminal bodies, connection points) while reducing volume in intermediate sections. This local quality approach reduces overall material consumption and production cost while maintaining sufficient mechanical strength for the application.
3Manufacturing precision
If uniform thickness is used throughout the bus bar element, then manufacturing is simple, but current density optimization is not achieved
Solution Approach 1:
The varying thickness design creates local quality variations that directly influence current density distribution. Thicker sections provide lower resistance paths for high current density areas, while thinner sections are sufficient for lower current density regions. This optimizes current density distribution throughout the bus bar element.
Solution Approach 2:
The invention changes the thickness parameter along the length of the bus bar element to match the current density requirements of different sections. This parameter variation enables precise control over current density distribution, improving electrical performance.
Data Source
Figure 1A~2
Figure 3~5
Figure 6~8
AI summary
The present subject matter relates to a bus bar element (10) for use in automobile applications and in charging stations. The bus bar element (10) includes a first terminal body (1) that extends along a first axis (X) has a first surface (5) and a second surface (4) defining a thickness along a third axis (Z). The first terminal body (1) is configured to electrically couple with an electrical interface. A main body (3) extends from the first terminal body (1). The said first terminal boy (1) has an opening (8) that is configured to receive a fastener wherein a first thickness (T1) of the opening (8) of the first terminal body (1) extending in the first axis (X) towards the main body (3) is greater than a second thickness (T2) of at least part of the first terminal body (1) extending towards an axial end.