Welded Current Branching Structure for Lightweight High-Current Distribution
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Solution Overview
Problem
Existing current branching devices using bus bars face challenges with increased weight and complexity due to larger sizes required for handling large currents, making processing difficult.
Innovation Solution
A current branching device that branches current without using a bus bar, utilizing a branch member welded to a main conductive wire at an intermediate portion for supplying current to multiple supply destinations, with branch conductive members welded to the branch member for different supply destinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of bus bars is increased to handle large currents, then the current handling capacity is improved, but the weight and thickness of the bus bar are increased, making processing difficult
Solution Approach 1:
The patent divides the single bus bar structure into multiple segments: a main conductive wire and multiple branch conductive members. Each segment can be optimized independently for weight and current capacity, allowing the system to handle large currents without requiring a single oversized bus bar, thus reducing overall weight and improving processability.
Solution Approach 2:
The patent transitions from a two-dimensional bus bar structure to a three-dimensional branched structure with the main conductive wire and multiple branch conductive members extending in different directions. This dimensional change allows current to flow through multiple parallel paths, increasing current handling capacity without increasing the cross-sectional area or weight of any single component.
2Power
If the size of bus bars is increased to handle large currents, then the current handling capacity is improved, but the processing difficulty is increased
Solution Approach 1:
By segmenting the conductive system into a main conductive wire and separate branch conductive members, each component can be manufactured and processed independently using standard techniques, avoiding the need to process a single large, complex bus bar structure that would be difficult to manufacture.
Solution Approach 2:
The patent combines multiple simpler conductive components (main conductive wire and branch conductive members) through welding to create a functional equivalent of a large bus bar system. This merging of simpler parts achieves the current handling capacity of a large bus bar while maintaining ease of manufacture.
3Adaptability or versatility
If a branch-type bus bar is used to branch current, then the current branching function is achieved, but the weight of the bus bar is increased
Solution Approach 1:
The patent segments the current branching function into a main conductive wire for primary current flow and separate branch conductive members for distributed current delivery. This segmentation allows each component to be optimized for its specific function and weight requirements, reducing the total weight compared to a single heavy branch-type bus bar structure.
Solution Approach 2:
The patent applies local quality by making the branch conductive members thinner and lighter than the main conductive wire, since they carry only a portion of the total current. This localized optimization of cross-sectional area based on actual current requirements reduces overall weight while maintaining the current branching function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables current branching to multiple electrical components while suppressing heat and noise generation, allowing for compact design, reduced weight, and lower manufacturing costs.
Implementation Method 1
a branch member welded to a main conductive wire at an intermediate portion of the main conductive wire
Implementation Method 2
at least one branch conductive member welded to the branch member
Data Source
AI summary
Provided is a current branching device for branching a current and supplying the current to a plurality of supply destinations, including a branch member welded to a main conductive wire at an intermediate portion of the main conductive wire for supplying a current to one supply destination, and at least one branch conductive wire welded to the branch member, for supplying a current to another supply destination.