Insulated Busbar Connection With BPA Alignment in Tight Spaces
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Solution Overview
Problem
Existing electrical connection systems for busbars in tight spaces, such as within vehicle batteries, are bulky and difficult to assemble, lacking a space-saving and efficient insulation solution.
Innovation Solution
An insulated connection system featuring an electrically insulating casing with a Busbar Positioning Assurance (BPA) member and anchor/locking units, allowing precise alignment and secure anchoring of busbars and connectors, ensuring correct positioning and preventing short circuits, while being easy to assemble and manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulated connection systems are used, then electrical insulation is provided, but the system becomes bulky and difficult to mount in tight spaces
Solution Approach 1:
The BPA member is inserted through the bar orifice of the second busbar and received within the connector passage of the insulating casing, creating a nested configuration where one component fits inside another. This nesting approach allows the alignment function to be integrated within the existing structure without adding external bulk, thereby maintaining electrical insulation reliability while reducing overall system volume for tight space applications
Solution Approach 2:
The BPA member serves multiple functions: it acts as an alignment tool during assembly, serves as a positioning assurance element to maintain correct busbar orientation, and can be integrated with the insulating casing structure. This multi-functionality eliminates the need for separate alignment tools and positioning devices, reducing the number of components and overall system volume while ensuring reliable electrical insulation
2Ease of manufacture
If conventional connection systems are used, then busbars can be connected, but assembly becomes complex and time-consuming
Solution Approach 1:
The BPA member is pre-configured with specific geometric features (such as rectangular cross-section or tapered shape) that enable self-alignment with the bar orifice and connector passage. This preliminary design of alignment features means that during assembly, no additional alignment operations are needed - the component automatically positions itself correctly when inserted, significantly reducing assembly time and complexity
Solution Approach 2:
The BPA member's geometry is designed to provide self-alignment and self-positioning capabilities. When the BPA member is inserted through the bar orifice, its shape causes it to automatically orient itself correctly within the connector passage without requiring external alignment tools or complex positioning procedures. This self-service characteristic simplifies the assembly process and reduces the skill level and time required for installation
Data Source
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AI summary
An insulated connection system for connecting a first busbar (10A) and a second busbar (10B) to at least a first connector (20A) and a second connector (20B), the second busbar (10B) including a bar orifice (13B) to connect the first connector (20A) to the first busbar (10A), having: - an electrically insulating casing (40) defining: • a first recess portion (41A) for accommodating a first connecting portion (11A) of the first busbar (10A), • a second recess portion (41B) for accommodating a second connecting portion (11B) of the second busbar (10B); • a sleeve portion (43) for accommodating a portion of the second busbar provided with the bar orifice (13B), - a busbar positioning assurance (BPA) member (50) of electrically insulating material configured to accommodate a portion of the first connector (20A) and to be received in the connector passage (43A, 43B) and the bar orifice (13B).