Adhesive Busbar Retainer for Sealed EV Battery Housings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for fixing busbars in housings face challenges such as noise, vibrations, and the risk of dielectric discharge, while also requiring a sealed and EMC-compatible connection, which is difficult to achieve with traditional screwed connections.
Innovation Solution
A retainer system with a retaining region and a contact region is proposed, where the contact region has a joining surface that adheres to the housing or a busbar holder, eliminating the need for a screwed connection and allowing for improved sealing, reduced component count, and enhanced EMC compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a screwed connection is used to fix the busbar in the housing, then the busbar is securely fixed and noise and vibrations are reduced, but the housing sealing is compromised and the complexity of the connection increases
Solution Approach 1:
The patent replaces the mechanical screwed connection system with a bonding system using adhesive or welding. The busbar is fixed to the housing through a bonding layer or welding process, eliminating the need for screws and threaded holes. This substitution maintains fixation stability while preserving housing sealing integrity, as no penetrations are required in the housing structure.
Solution Approach 2:
The patent introduces an intermediary bonding layer or welding interface between the busbar and housing. This intermediary element provides the mechanical connection function while allowing the housing material to remain continuous and sealed. The bonding layer acts as a mediator that transfers mechanical loads without compromising the sealing function of the housing.
2Strength
If a screwed connection is used to fix the busbar, then the connection is mechanically strong, but the number of components increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the busbar and housing into a more integrated structure by using bonding or welding instead of separate fastening components. The connection is achieved through a direct bonding process or bonding layer, eliminating the need for separate screws, washers, and threaded inserts. This merging reduces component count while maintaining connection strength through the bonded or welded joint.
Solution Approach 2:
The patent extracts and removes the screw fastening components from the connection system. By eliminating screws, washers, and threaded holes, the design simplifies the connection structure to essentially two main components (busbar and housing) connected through a bonding interface. This extraction of unnecessary components reduces assembly complexity and part inventory requirements.
3Quantity of substance
If the busbar cross section is reduced to save material and weight, then material usage and weight decrease, but heat dissipation capability deteriorates
Solution Approach 1:
The patent applies local quality enhancement by adding bonding material or welding interfaces at specific locations where thermal management is critical. The bonding layer or welding zones are strategically positioned to provide enhanced heat dissipation pathways without requiring an increase in the overall busbar cross section. This localized approach improves thermal performance where needed while maintaining material efficiency.
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
The retainer system effectively reduces noise and vibrations, enhances sealing against liquids, improves electromagnetic compatibility, and compensates for manufacturing tolerances, all while minimizing the weight and number of components in the busbar assembly.
Implementation Method 1
a joining surface of the contact region is adapted to adhere to a correspondence joining surface of the housing or to a busbar holder arranged in the housing
Data Source
AI summary
A busbar assembly for installation in a battery for a motor vehicle, comprising a housing in which at least one busbar is arranged, and a retainer for fixing the busbar in the housing, where the retainer comprises a retaining region and a contact region, wherein the retaining region is adapted to retain the at least one busbar, and the contact region is adapted to fix the retainer in the housing.