Annular Contact Spring Connection for Vibration-Stable Busbar Posts
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Solution Overview
Problem
Existing electrical connection methods using busbars and laser welding result in poor electrical contact in vibrating environments and hinder quick insertion and removal, making them inconvenient to use.
Innovation Solution
An electrical connection module with a receiving cavity and an annular contact spring that undergoes elastic deformation to make radial electrical contact with a conductive post, using a limiting element to prevent axial movement and allowing for quick insertion and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is used to connect busbar to battery cell pole, then connection strength is improved, but insertion and removal functions are lost
Solution Approach 1:
The connection system is divided into three independent components: the busbar with receiving cavity, the contact spring, and the battery cell pole. This segmentation allows the busbar and battery cell to be connected and disconnected by simply inserting/removing the pole, while the contact spring maintains continuous electrical contact, thus achieving both strong connection and easy operation.
Solution Approach 2:
The contact spring is designed as a dynamic component that can automatically deform and adapt. When the battery cell pole is inserted, the contact spring elastically deforms to wrap around the pole and establish electrical contact. This dynamic behavior enables the connection to maintain strength while allowing easy insertion and removal without welding.
2Reliability
If bolt fixing method is used for electrical connection, then connection reliability is improved, but operation complexity increases
Solution Approach 1:
The complex bolt fixing mechanism is extracted and replaced with a simple insertion-based system. The contact spring is pre-installed in the busbar's receiving cavity, so during operation, users only need to insert the battery cell pole to establish connection, eliminating the need for bolts and significantly reducing operation complexity while maintaining reliability.
Solution Approach 2:
The contact spring is designed to automatically perform the connection function when the battery cell pole is inserted. The spring self-adjusts its deformation state to establish and maintain electrical contact without requiring external fastening operations, making the system self-servicing and operationally simple.
3Ease of manufacture
If plane to plane contact is used between busbars, then manufacturing simplicity is improved, but electrical contact quality deteriorates in vibration environments
Solution Approach 1:
The contact spring is designed with a curved, annular shape that wraps around the cylindrical battery cell pole. This curved geometry provides point contact and radial clamping force, ensuring stable electrical contact that resists vibration, unlike flat plane-to-plane contact which easily loses contact under vibrational stress.
Solution Approach 2:
The contact spring's elastic properties are utilized to change the contact parameters dynamically. The spring maintains constant radial contact force on the battery cell pole through its elastic deformation, ensuring stable electrical contact quality in vibration environments, whereas rigid plane contact cannot adapt to vibrations.
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
Ensures reliable electrical contact even in vibrating environments while enabling fast and convenient connection and disconnection.
Implementation Method 1
the contact spring is adapted to undergo elastic deformation along a radial direction of the receiving cavity to make radial electrical contact with the inserted conductive post
Data Source
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AI summary
The present invention discloses an electrical connection module and an electrical connection assembly. The electrical connection module comprises of: an electrical connection member (1) formed with a receiving cavity (101); and a contact spring (13) which is provided in the receiving cavity (101). The electrical connection member (1) has an outer peripheral wall (11) surrounding the receiving cavity (101), as well as a top wall (12) and a bottom opening (13a) opposite to the top wall (12) in an axial direction of the receiving cavity (101); the contact spring (13) is annular in shape so as to be able to be fitted like a ring onto a conductive post (21) of a connected object (2) inserted from the bottom opening (13a); the contact spring (13) is adapted to undergo elastic deformation along a radial direction of the receiving cavity (101) to make radial electrical contact with the inserted conductive post (21), so that the electrical connection member (1) is capable of being electrically connected to the connected object (2) via the contact spring (13). In the present invention, the contact spring is fitted onto the conductive post like a ring and makes electrical contact with it, ensuring reliable electrical contact even in a vibrating environment. Additionally, the present invention enables quick insertion and removal, making it very convenient to use.