Boltless Battery Busbar Connectors for Fast, Secure Module Assembly
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Solution Overview
Problem
Conventional power distribution components in vehicles face challenges such as space constraints, harsh operating conditions, vibration, and temperature fluctuations, leading to connector failures and increased warranty costs due to incorrect installations and dislodged connectors.
Innovation Solution
A battery pack with a boltless connector system that includes a female connector assembly, conductor (busbar), and a boltless male connector assembly, facilitating mechanical and electrical connections between battery modules without the need for bolts, thereby reducing failure modes and assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional bolted connector systems are used, then mechanical strength and electrical connection are achieved, but assembly time increases and installation complexity increases
Solution Approach 1:
The invention extracts and eliminates the bolts from the connector system, transitioning from a bolted connection system to a boltless push-to-connect system. This removes the time-consuming bolt tightening process while maintaining connection reliability through a spring-loaded contact mechanism that provides automatic mechanical engagement and electrical connection.
Solution Approach 2:
The connector components are pre-assembled and pre-configured during manufacturing, with spring elements and contact surfaces prepared in advance. This preliminary preparation allows for rapid field installation without requiring complex assembly procedures or specialized tools, thereby reducing assembly time while ensuring reliable connection.
2Reliability
If conventional bolted connector systems are used, then secure connections are achieved, but device complexity and installation difficulty increase
Solution Approach 1:
The connector system is designed to be self-assembling through a push-to-connect mechanism where the male connector automatically engages with the female connector upon insertion. The spring-loaded design provides self-centering and self-locking functionality, eliminating the need for external fastening operations and reducing installation complexity to a simple push motion.
Solution Approach 2:
The invention replaces the complex mechanical bolt tightening system with a simplified spring-loaded contact system. Instead of requiring threaded fasteners, nuts, and torque application, the design uses elastic deformation of spring elements to provide both mechanical retention and electrical contact, significantly reducing installation complexity.
3Reliability
If correct installation procedures are followed, then connector reliability is maintained, but warranty costs still increase due to installation errors
Solution Approach 1:
The boltless push-to-connect design is inherently self-explanatory and self-correcting, requiring no specialized training or complex procedures. The simple push motion is intuitive and self-evident, making the system easy for anyone to install correctly on the first attempt, thereby reducing warranty costs associated with installation errors.
Solution Approach 2:
Instead of requiring the installer to perform complex tightening and securing operations, the design inverts the approach by using a simple insertion motion that automatically creates the secure connection. This reversal of the traditional assembly sequence from complex-to-simple reduces installation difficulty and minimizes human error.
Data Source
AI summary
The invention relates to a battery pack for use in a power management system of an application, such as a motor vehicle, ship or train. The battery pack includes a boltless busbar having a first male terminal assembly and a second male terminal assembly. A first battery module has: (i) an internal battery cell positioned within a battery module housing (ii) a boltless female connector assembly having a female first terminal housing associated with said battery module housing and a first female terminal assembly positioned within the first female terminal housing. A second battery module has: (i) an internal battery cell positioned within a battery module housing (ii) a boltless female connector assembly having a second female terminal housing associated with said battery module housing and a second female terminal assembly positioned within the second female terminal housing. When the first male terminal assembly is positioned within an extent of the first female terminal assembly and the second male terminal assembly is positioned within an extent of the second female terminal assembly, the boltless busbar electrically couples the first battery module to the second battery module.