Battery Distribution Unit with Integrated Cross Terminals
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Solution Overview
Problem
Conventional battery distribution units (BDUs) are large, complex, and costly due to numerous components and lack design flexibility, making them difficult to integrate with other devices and adapt to different orientations and spaces.
Innovation Solution
A compact BDU design featuring a strip busbar and cross terminals that allow for flexible electrical connections between electronic devices, reducing the number of components and assembly time, while maintaining mechanical and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bolt/nut connections are used in BDU, then reliable electrical connection is achieved, but the number of components increases and assembly time increases
Solution Approach 1:
The patent combines the bolt/nut connection components into an integrated terminal structure where the terminal body incorporates the fastening mechanism. The terminal includes an integrated fastening feature that directly engages with the device, eliminating the need for separate bolts and nuts while maintaining reliable electrical and mechanical connections.
Solution Approach 2:
The terminal design serves multiple functions simultaneously: it provides electrical conduction through the conductive body, mechanical fastening through the integrated fastening feature, and structural support for the blade terminal. This multi-functional design reduces the overall component count while maintaining connection reliability.
2Reliability
If conventional bolt/nut connections are used in BDU, then reliable electrical connection is achieved, but assembly time increases
Solution Approach 1:
The fastening feature is pre-integrated into the terminal structure during manufacturing, so that during assembly, the terminal can be directly installed with the fastening mechanism already in place. This eliminates the need for separate fastening operations, reducing assembly time while maintaining reliable connections.
Solution Approach 2:
By merging the fastening components into the terminal body, the assembly process is simplified to a single installation step rather than multiple steps involving separate bolts and nuts, thereby reducing assembly time without compromising connection reliability.
3Ease of manufacture
If customized busbars with stamped blades are used, then electrical connections are established, but the blade position tolerance is difficult to control and blade orientation accommodation is difficult
Solution Approach 1:
The terminal design incorporates a localized engagement structure where the blade terminal engages with a specifically designed receptacle feature. This localized design ensures precise positioning and orientation control at the critical connection point, improving manufacturing precision while maintaining ease of manufacture for the overall structure.
4Ease of manufacture
If multiple layer busbar arrangements are used, then electrical connections are established, but the overall cost and package size increase
Solution Approach 1:
The terminal design transitions from a multi-layer busbar arrangement to a three-dimensional integrated structure where the blade terminal engages vertically with the terminal body. This dimensional change allows for more compact packaging while maintaining all necessary electrical connections within a smaller overall volume.
5Ease of manufacture
If conventional BDU designs are used, then electrical connections are established, but design flexibility to adapt to different orientations and available spaces is limited
Solution Approach 1:
The terminal design incorporates flexible engagement features that can accommodate different orientations and mounting configurations. The blade terminal and receptacle structure are designed to allow installation in various orientations, providing adaptability to different available spaces and mounting surfaces while maintaining reliable electrical connections.
Data Source
AI summary
A battery distribution unit (BDU) for holding a first electronic device having a first blade terminal extending therefrom and a second electronic device having a second blade terminal extending therefrom includes a BDU housing, a strip busbar received in the BDU housing, and first and second cross terminals received in the BDU housing. The first cross terminal receives the strip busbar at a first end thereof and is configured to receive the first blade terminal at a second end thereof. The second cross terminal receives the strip busbar at a first end thereof and is configured to receive the second blade terminal at a second end thereof.