POWER LINE ARRANGEMENT FOR A VEHICLE

Abstract

This document describes a conductor rail assembly (100) for a vehicle. The conductor rail assembly (100) comprises at least one conductor rail (102), each of which includes at least one hole (104). The conductor rail assembly (100) further comprises at least one screw (106) configured with the at least one hole (104) for fastening the conductor rail assembly (100) to the vehicle. The at least one screw (106) is a captive screw permanently connected to the corresponding hole (104) to prevent the screw (106) from separating from the corresponding conductor rail (102).

Description

TECHNICAL AREA

[0001] The present invention relates to the field of busbars. In particular, the present invention relates to a busbar arrangement for a battery pack of a vehicle. BACKGROUND

[0002] The background description contains information that may be useful for understanding the present invention. It does not constitute an admission that the information contained herein forms part of the prior art or is relevant to the present invention, or that any publication to which express or implicit reference is made forms part of the prior art.

[0003] In the automotive industry, busbars serve as a distribution system for electrical current from the battery pack to various parts of the vehicle. However, the space required for these busbars, especially in certain configurations, can be greater than for conventional cable systems. This increased space requirement presents a challenge, particularly in compact vehicle designs. Furthermore, the fasteners for these busbars, such as screws, can loosen during vehicle operation and fall into the battery housing. Additionally, welds in the busbars can break or develop hairline cracks over time due to the dynamic conditions within the vehicle.

[0004] The nature of the electrical components within the battery increases the risk of short circuits, especially as the number of components increases. This risk is further amplified by the presence of loose or damaged fasteners and inadequate welds. To overcome these drawbacks, the busbars must be secured with improved fasteners to reduce installation time while ensuring reliable operation under all vehicle operating conditions.

[0005] In the past, efforts have been made to facilitate the mounting of battery packs in vehicles. For example, patent document WO2024037805A1 discloses a connecting device for battery cells of a traction battery, wherein the connecting device is designed to compensate for tolerances between two battery cells of the traction battery in spatial directions. The connecting device comprises a busbar, the first end of which is configured for electrical connection to a first battery cell and the second end of which is configured for connection to a second battery cell, thereby electrically connecting the two battery cells. The connecting device further comprises a fastening device by means of which the connecting device can be attached in various relative positions to a housing part of a component of the traction battery for the purpose of tolerance compensation.

[0006] However, the cited reference does not offer a solution for securing the fasteners associated with the connector. As a result, the fastener could fall onto or penetrate the battery compartment, potentially causing physical damage to the batteries and short circuits. Therefore, the cited reference does not provide an effective solution to the aforementioned problem.

[0007] Therefore, there is a need to find a simple, safe and cost-effective solution for attaching the busbar assembly to the battery housing in vehicles. TASK OF INVENTION

[0008] A general object of the present invention is to provide a busbar arrangement with improved fastening means that prevent screws and other fastening means from loosening and falling onto the battery housing.

[0009] The object of the present invention is to reduce the risk of electrical short circuits in the vehicle battery by eliminating the possibility of loose fasteners coming into contact with sensitive components.

[0010] One object of the present invention is to reduce the cycle time in the assembly process by integrating a more efficient and reliable busbar assembly.

[0011] The object of the present invention is to optimize the space requirement for busbars within the battery housing in order to enable more compact and efficient vehicle designs. SUMMARY OF THE INVENTION

[0012] Aspects of the present invention relate to the field of busbar arrangements for vehicles. In particular, the present invention relates to a busbar arrangement for a vehicle battery pack that prevents fasteners attached to the assembly from falling off, thereby avoiding damage and short-circuit conditions.

[0013] According to one aspect, the present invention relates to a busbar assembly for a vehicle. The assembly comprises at least one busbar, each having at least one hole. The assembly further comprises at least one screw formed with the at least one hole for fastening the busbar assembly to the vehicle. The at least one screw is a captive screw, permanently connected to the corresponding hole to prevent the screw from separating from the busbar.

[0014] In one aspect, the busbar assembly comprises at least one washer configured with the at least one screw to permanently secure the at least one screw to the corresponding busbar. The at least one washer is located on a side opposite a screw entry face of the busbar and is configured to engage a threaded section of the screw to prevent movement of the screw towards the entry face of the busbar.

[0015] In one aspect, the screw comprises a shank section that is positioned between a head and the threaded section of the screw, wherein the shank section has a smaller diameter than the threaded section, so that the washer is positioned freely movable over the shank section.

[0016] One aspect is that the washer has an internal thread that matches the thread of the corresponding screw, so that the screw can be guided through by screwing it in and remain above the shank of the screw.

[0017] One aspect is that the washer has a cut-off section. After insertion, this cut-off section can be pressed through the threaded portion of the screw to reduce the inner diameter of the washer, allowing it to remain above the shank section of the screw.

[0018] In one aspect, the washer is a captive washer, which allows the washer to be inserted only through the threaded section of the screw, so that the washer remains above the shaft section.

[0019] In one aspect, each of the at least one busbar includes at least one clip that is integrally formed with the busbar and extends laterally from it. Furthermore, the at least one hole is located on the corresponding clip.

[0020] In one aspect, at least one busbar containing the clip is provided with an insulating coating.

[0021] In one aspect, the busbar assembly comprises a first busbar and a second busbar, each having at least one laterally extending clip and at least one hole located above the at least one clip. The first busbar is configured to be placed above the second busbar, with the at least one screw passing through the holes of both the first and second busbars, and the clips of the two busbars positioned between the screw head and the washer.

[0022] One aspect is that at least one clip of the second busbar contains a protruding positioning device and the clip of the first busbar has a corresponding slot, so that the positioning device engages in the slot and facilitates the alignment of the two busbars.

[0023] Various objects, features, aspects and advantages of the invention will become clearer from the following detailed description of preferred embodiments together with the accompanying drawings, in which the same numbers represent the same components. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings serve to further understand the present invention and are an integral part of this description. The drawings illustrate exemplary embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. Fig. Figure 1 shows an exemplary diagram of the proposed busbar arrangement configured with a battery housing of a vehicle according to embodiments of the present invention. Fig. Figure 2 shows a sectional view of the busbar arrangement, which is conventionally fastened with clips of the busbar arrangement using a conventional screw. Fig. Figure 3 shows an exemplary sectional view of the captive screw together with a washer for fastening clips of the busbar arrangement according to the embodiments of the present invention. Fig. Figure 4A shows an exemplary representation of the attached clips, which shows a slot as a fixing feature on the first clip of the first busbar and a drift angle in the first busbar and the second busbar of the busbar arrangement according to embodiments of the present invention. Fig. Figure 4B shows an exemplary representation of a forward positioning device of the second clip of the second busbar in an engagement position in the slot of the first clip, showing the correct alignment of the two clips according to embodiments of the present invention. Fig. Figure 4C shows an exemplary representation of a gusset configured between the second laterally extended clip and the second busbar to reinforce the connection, in accordance with embodiments of the present invention. DETAILED DESCRIPTION

[0025] A detailed description of embodiments of the invention, illustrated in the accompanying drawings, follows. The embodiments are described in sufficient detail to ensure the invention is clearly understandable. However, this level of detail is not intended to limit foreseeable variations of embodiments; rather, it aims to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the present invention as defined by the accompanying claims.

[0026] The embodiments described here relate to a busbar arrangement for a vehicle battery pack, which prevents the fastening elements connected to the assembly from falling off and thereby avoids any damage and short-circuit conditions.

[0027] According to one aspect of the present invention, a busbar assembly for a vehicle is developed. The assembly can comprise at least one busbar, each busbar having at least one hole. The assembly can further comprise at least one screw configured with the at least one hole for fastening the busbar assembly to the vehicle. The screw can be a captive screw, permanently connected to the corresponding hole to prevent the screw from separating from the corresponding busbar.

[0028] In one embodiment, the busbar assembly can include at least one washer configured with the screw to permanently hold the screw to the corresponding busbar. The washer can be located on a side of the busbar opposite the insertion side of the screw and can be configured to engage in a threaded section of the screw to prevent movement of the screw toward the insertion side of the busbar.

[0029] In one embodiment, the screw can have a shank part located between a head and the threaded part of the screw, wherein the shank part has a smaller diameter than the threaded part, so that the washer can be arranged freely or movably over the shank part.

[0030] In one embodiment, the washer can have an internal thread that matches the thread of the corresponding screw, so that the screw can be passed through by screwing it in to remain above the shank part of the screw.

[0031] In one embodiment, the washer can have a cut-off portion. After insertion, the cut-off portion can be pressed through the threaded section of the screw to reduce the internal diameter of the cut-off washer, allowing it to remain above the shank section of the screw.

[0032] In one embodiment, the washer can be a captive washer that allows the washer to be inserted only through the threaded section of the screw, so that the washer remains above the shaft section.

[0033] In one embodiment, each of the busbars can include at least one clip that is integrally formed with the busbar and extends rearward from the corresponding busbar. Furthermore, the hole can be arranged on the corresponding clip.

[0034] In one embodiment, the busbar, including the clip, can be provided with an insulating coating.

[0035] In one embodiment, the busbar assembly can comprise a first busbar and a second busbar, each having at least one laterally extending clip and at least one hole located above the corresponding clip. The first busbar can be configured to be positioned above the second busbar, with the screw passing through the holes of the first and second busbars and the clips of both busbars positioned between the screw head and the washer.

[0036] In one embodiment, the clip of the second busbar can have a protruding positioning aid and the clip of the first busbar can have a corresponding slot, so that the positioning aid engages in the slot and facilitates the alignment of the two busbars.

[0037] With reference to the Fig. In Figures 1 and 3 to 4C, the proposed busbar arrangement 100, configured with a vehicle battery housing 112, is disclosed. In one embodiment, the busbar arrangement 100 may comprise at least one busbar 102-1, 102-2 (hereinafter collectively referred to as busbar 102), each busbar 102 comprising at least one hole 104 (hereinafter collectively referred to as hole or holes 104), as shown in Figures 1 and 3 to 4C. Fig. Figure 4B shows the busbars 102-1, 102-2 comprising a busbar housing. The busbar assembly 100 may further comprise at least one screw 106-1, 106-2 (hereinafter collectively referred to as screw 106) configured with each hole 104 of the busbars 102-1, 102-2 for fastening the busbar assembly 100 in the vehicle. Each of the busbars 102 may comprise at least one clip 108-1 to 108-4 (hereinafter collectively referred to as clip 108) formed integrally with the busbar and which may extend laterally from the respective busbar 102, the hole 104 being arranged on the corresponding clip 108.

[0038] In one embodiment, the screw 106 can be a captive screw that can be permanently connected to the corresponding hole 104 of the busbar 102 to prevent the screw 106 from separating from the busbar 102. In another embodiment, the busbar assembly 100 can comprise a first busbar 102-1 with laterally extending clips 108-1 and 108-2 and a hole 104 located above the clips 108-1 and 108-2, respectively. Furthermore, the busbar assembly 100 can comprise a second busbar 102-2 with laterally extending clips 108-3 and 108-4 and a hole located on the corresponding clips 108-3 and 108-4.

[0039] In one embodiment, the first busbar 102-1 can be configured to be placed above the second busbar 102-2, with the screws 106-1, 106-2 being guided through corresponding holes 104 of the first busbar 102-1 and the second busbar 102-2 respectively, and the clips 108-1 and 108-3 of the two busbars 102-1, 102-2 being arranged between the head of the respective screws 106-1, 106-2 and a washer 302, as shown in Fig. 3 shown.

[0040] In another embodiment, the busbar 102, including the clip 108, can be provided with an insulating coating 110, as shown in Fig. Figure 3 shows the coating 110 being of different colors to easily identify the polarity of the charge carried by the busbars 102; this makes it easier for the technician to connect the identified busbar 102 with the correct polarity in the circuit loop. The insulating layer 110 can be manufactured separately by injection molding to encase the busbars 102.

[0041] In Fig. Figure 2 shows an exemplary sectional view 200 of the busbar assembly 100, which is fastened to the busbar assembly 100 using clips 108 and a conventional screw 202. The conventional screw 202 is typically designed such that the diameter of the threaded section 206 and the diameter of the shank 208 of the screw 202 are the same, and the screw 202 is fastened primarily without a captive washer. Consequently, due to vibrations, shocks, and jolts to which the moving vehicle is subjected, the conventional screw 202 can detach from the busbar and fall onto adjacent components, as there is no provision for securing the screw 202. The proposed busbar assembly 100 overcomes this problem by using the captive screw 106 together with a washer 302 to fasten the clips 108 of the busbar assembly 100.

[0042] With reference to Fig. Figure 3 discloses an exemplary sectional view 300 of the proposed captive screw 106 together with a washer 302 for fastening clips 108 of the busbar assembly 100. In one embodiment, the captive screw 106 of the present invention is a fastening element that can be configured to remain attached to the busbars 102. In contrast, the conventional screw 202 can be unscrewed from the threaded hole 104 of the busbars 102, thus allowing it to easily detach from the busbars 102. However, the captive screw 106 of the present invention can rotate freely in the holes 104 of the busbars 102, with some axial movement depending on the difference in the diameter of the threads of the captive screw 106 and the shank diameter, but is unable to fall out or detach from the busbars 102.Consequently, the captive screw 106 cannot fall off by itself.

[0043] In one embodiment, the busbar assembly 100 can include at least one washer 302 configured with the captive screw 106 to hold it permanently to the captive screw 106 and the corresponding busbar 102. In one embodiment, the washer 302 can be arranged on a side opposite the entry side of the screw of the busbar 102, wherein the washer 302 can be configured to engage with a threaded section 304 of the screw 106 to prevent movement of the screw 106 toward the entry side of the busbar 102.

[0044] The captive screw 106 can further have a shank section 306 which is arranged between a head 308 and the threaded section 304 of the screw 106, wherein the shank section 306 has a smaller diameter than the threaded section 304, so that the washer 302 can remain freely or movably arranged over the shank section 306.

[0045] In one embodiment, the captive screw 106 can be used with a retaining flange or a retaining washer that remains on the shank portion 306 unless it is unscrewed and forcibly removed. Furthermore, the washer 302 can have an internal thread that matches the thread 304 of the corresponding screw 106, so that the screw 106 can be screwed through it, leaving the washer 302 in place over the shank portion 306 of the screw 106.

[0046] In one embodiment, the washer 302 can have a cut-off section which can be configured to be pressed through the threaded section 304 of the screw 106 after insertion to reduce the inner diameter of the cut-off washer, so that the washer 302 remains above the shank section 306 of the screw 106.

[0047] In one embodiment, the washer 302 can be a captive washer (e.g. SWAS-SC) which makes it possible to insert the washer 302 only through the threaded section 304 of the screw 106, so that the washer 302 remains above the shank section 306.

[0048] In one embodiment, the busbar assembly 100, consisting of the first busbar 102-1 and the second busbar 102-2, can be fastened with the respective clips 108, the captive screw 106, and the washer 302. The captive screw 106 can first be inserted through the hole 104 formed by the clips 108 and then to the washer 302 located between the underside of the clip 108-3 and the top side of the component to be fastened (busbars 102). The captive screw 106 can then be screwed in until the shank 306 is engaged to secure the screw 106 to the busbar.

[0049] With reference to Fig. Figures 4A to 4C disclose an exemplary illustration 400 showing a localization means on the attached clips 108. In one embodiment, a slot 402 can be provided as a localization feature on the first clip 108-1 of the first busbar 102-1, as shown in Fig. 4A shown, and a corresponding projecting fastening 406 on the second clip 108-3 of the second busbar 102-2, as shown in Fig. 4B shown, configured. The preceding fastening 406 of Fig. 4B can engage in the slot 402 of the first clip 108-1, thus facilitating the alignment of the two busbars 102-1 and 102-2. This can ensure correct alignment of the two clips 108-1 and 108-3 with the holes 104. Furthermore, as shown in Fig. As shown in Figure 4A, a relief angle 404 can also be provided on the two busbars of the busbar assembly 100. In an exemplary embodiment, the relief angle 404 can be kept at 0.5°, but is not limited to this. Similarly, another feature of a gusset 408 between the second laterally extended clip 108-3 and the second busbar 102-2 can be configured to reinforce the connection and strengthen the busbar assembly 100, as shown in Figure 4A. Fig. 4C shown.

[0050] The present invention overcomes the problems associated with existing solutions by providing a simple, safe, and cost-effective busbar arrangement 100 with improved fastening means that prevent fasteners from loosening and falling into the battery housing 112. This reduces the risk of electrical short circuits within the battery in vehicles, as the possibility of loose fasteners coming into contact with electrical components is eliminated.

[0051] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention can be developed without deviating from the fundamental scope of the invention. The scope of the invention is defined by the following claims. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person with ordinary technical knowledge to manufacture and use the invention when combined with information and knowledge available to such a person. ADVANTAGES OF THE INVENTION

[0052] The present invention provides a busbar arrangement with improved fastening means that prevent screws and other fastening means from loosening and falling into the battery housing.

[0053] The present invention reduces the risk of electrical short circuits within the vehicle battery by preventing loose fasteners from coming into contact with sensitive components.

[0054] The present invention reduces the assembly time in the assembly process by integrating a more efficient and reliable busbar mounting system.

[0055] The present invention optimizes the space required for busbars within the battery housing, thus enabling more compact and efficient vehicle designs. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 2024037805A1

[0005]

Claims

[1] A conductor rail arrangement (100) for a vehicle, wherein the conductor rail arrangement (100) comprises the following: at least one busbar (102), each of the at least one busbar (102) having at least one hole (104); and at least one screw (106) configured with the at least one hole (104) for fastening the busbar assembly (100) of the vehicle: wherein the at least one screw (106) is a captive screw which is inseparably connected to the corresponding hole (104) in order to prevent the screw (106) from separating from the corresponding busbar (102). [2] Busbar arrangement (100) according to claim 1, wherein the busbar arrangement (100) comprises at least one washer (302) configured with the at least one screw (106) to hold the at least one screw (106) permanently on the corresponding busbar (102), wherein the at least one washer (302) is arranged on a side opposite a screw insertion side of the busbar (102) and is configured to engage with a threaded section (304) of the screw (106) to prevent movement of the screw (106) towards the insertion side of the busbar (102). [3] Busbar arrangement (100) according to claim 2, wherein the screw (106) has a shaft section (306) which is arranged between a head (308) and the threaded section (304) of the screw (106), wherein the shaft section (306) has a smaller diameter than the threaded section (304), and wherein the washer (302) is arranged to be freely movable over the shaft section (306). [4] Busbar arrangement (100) according to claim 3, wherein the washer (302) has an internal thread that matches the thread of the corresponding screw (106) so that the screw (106) can be passed through by screwing it in to remain above the shank section (306) of the screw (106). [5] Busbar arrangement (100) according to claim 3, wherein the washer (302) has a cut-off section and wherein the cut-off section is such that, after insertion through the threaded section (304) of the screw (106), it is pressed to reduce the inner diameter of the washer (302) so that the washer (302) remains above the shank section (306) of the screw (106). [6] Busbar arrangement (100) according to claim 3, wherein the washer (302) is a captive washer which allows the washer (302) to be inserted only through the threaded section (304) of the screw (106) and remains above the shaft section (306). [7] Busbar arrangement (100) according to claim 1, wherein each of the at least one busbar (102) comprises at least one clip (108) which is formed integrally with the busbar and extends laterally from the at least one busbar (102), and wherein the at least one hole (104) is arranged on the corresponding clip (108). [8] Busbar arrangement (100) according to claim 7, wherein the at least one busbar (102) including the clevis (108) is provided with an insulating coating (110). [9] Busbar arrangement (100) according to claim 8, wherein the busbar arrangement (100) comprises a first busbar (102-1) and a second busbar (102-2), each having the at least one laterally extending clip (108) and the at least one hole (104) located above the at least one clip (108), wherein the first busbar (102-1) is configured to be placed above the second busbar (102-2), wherein the at least one screw (106) passes through the holes (104) of the first busbar (102-1) and the second busbar (102-2), and wherein the clips (108) of the two busbars (102-1, 102-2) are arranged between the head (308) of the screw (106) and the washer (302). [10] Busbar arrangement (100) according to claim 7, wherein the at least one terminal (108-3) of the second busbar (102-2) comprises a projecting fastening (406) and the terminal (108-1) of the first busbar (102-1) comprises a corresponding slot (402) so that the fastening (406) engages in the slot (402) and facilitates the alignment of the two busbars (102).

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