Bus Bar Connection Structure With Elastic Contact Pressure Retention
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Solution Overview
Problem
Existing connection structures between battery modules and fuse contactor units in electric vehicles often fail to secure adequate contact pressure between conductors, leading to potential electrical connectivity issues.
Innovation Solution
A connection structure comprising a first and second bus bar with through holes, a connection member with overhanging portions, and an elastic member that secures contact pressure by biasing the bus bars together, ensuring stable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a power supply-side male terminal is directly attached to and detached from each of a plurality of power reception-side female terminals, then the connection structure is simple, but the contact pressure between conductors cannot be secured
Solution Approach 1:
A connection member with a shaft and overhanging portions is introduced as an intermediary component between the bus bars. The shaft passes through both bus bars while the overhanging portions engage with recessed surfaces, creating a mediator that transmits and maintains contact pressure between the conductors without requiring direct terminal attachment.
Solution Approach 2:
An elastic member is incorporated into the connection structure, providing dynamic elasticity that automatically maintains contact pressure. The elastic member can deform and recover, ensuring continuous pressure on the conductors even under varying conditions, thus securing reliable electrical connection without excessive fastening force.
2Reliability
If excessive fastening force is applied to secure contact pressure, then the contact pressure is sufficient, but the risk of damaging components increases and the operation becomes difficult
Solution Approach 1:
The elastic member provides dynamic force multiplication, where a small fastening force applied to the connection member generates sufficient contact pressure on the conductors through elastic deformation. This eliminates the need for excessive fastening force while ensuring reliable electrical connection.
Solution Approach 2:
The connection structure changes the force parameter by using elastic deformation to amplify the fastening force. The elastic member's spring constant is designed to convert moderate fastening force into adequate contact pressure, making the operation easy while maintaining reliable electrical connection.
3Reliability
If multiple fastening points are used to secure contact pressure, then the contact pressure is distributed, but the number of components and fastening operations increases
Solution Approach 1:
Multiple fastening functions are merged into a single connection member. The shaft with overhanging portions engages with recessed surfaces on both bus bars simultaneously, distributing contact pressure at multiple points while using only one component instead of multiple separate fasteners.
Solution Approach 2:
The connection member serves multiple functions: it provides mechanical fastening, distributes contact pressure across multiple engagement points, and maintains electrical connection. This multi-functionality reduces the overall number of components needed in the system.
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 solution effectively maintains contact pressure between bus bars, facilitating easy and reliable electrical connections while reducing the need for excessive fastening force and component count.
Implementation Method 1
an elastic member through which the shaft penetrates... The elastic member has an outer peripheral diameter larger than the circumference and an inner peripheral diameter smaller than a maximum diameter of the first overhanging portion
Data Source
AI summary
A connection structure includes: a first bus bar including a first through hole; a second bus bar including a second through hole; a connection member including a shaft, a first overhanging portion, and a second overhanging portion; and an elastic member through which the shaft penetrates. The elastic member has an outer peripheral diameter larger than the circumference of the virtual circle and an inner peripheral diameter smaller than a maximum diameter of the first overhanging portion. The second overhanging portion is insertable into the first through hole and the second through hole while being fitted into a recess defined by the first recessed surface of the first through hole and the second recessed surface of the second through hole at a first rotational position; and the second overhanging portion overlaps a second pressed surface when viewed in a penetrating direction at a second rotational position.