Busbar Cage and Bushing Layout for Touch-Safe HV Battery Terminals
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Solution Overview
Problem
High-voltage battery packs pose safety risks due to exposed terminals, which can cause electrical shocks to operators, and existing solutions like terminal covers increase costs and waste.
Innovation Solution
An electrical connection unit design featuring a busbar assembly with an annular bushing and fastener configuration that prevents human contact with terminals by ensuring the annular bushing is positioned between inner and outer walls, preventing fingertips from reaching the terminals in both unassembled and assembled configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal covers are provided to prevent human contact with terminals, then safety is improved, but cost and parts count increase
Solution Approach 1:
The patent merges the protective function with the existing terminal structure by integrating the protective features directly into the busbar and terminal assembly. The busbar cage structure and positioning features are combined with the terminal mounting structure, eliminating the need for separate protective covers while maintaining safety functionality.
Solution Approach 2:
The busbar cage structure serves multiple functions: it provides mechanical support for the terminal, ensures proper positioning through integrated features, and simultaneously acts as the protective barrier. This multi-functionality eliminates the need for dedicated protective covers, reducing parts count while maintaining safety.
2Reliability
If terminal covers are provided to prevent human contact with terminals, then safety is improved, but recycling and waste management become more difficult
Solution Approach 1:
By merging the protective function into the existing metal busbar and terminal assembly structure, the design eliminates separate protective cover components. This integration means fewer materials need to be managed during recycling, and the metal components can be fully recycled without dealing with composite or plastic cover materials.
3Reliability
If the busbar cage structure is designed to prevent finger access, then safety is improved, but manufacturing complexity increases
Solution Approach 1:
The protective structure is segmented into discrete functional elements: the busbar cage with its openings, the positioning features, and the terminal mounting structure. Each segment can be manufactured independently using standard processes, and then assembled together, maintaining ease of manufacture while achieving the safety function.
Solution Approach 2:
The design applies protective features only where needed - the busbar cage structure provides protection at the terminal exposure points, while other areas maintain standard manufacturing simplicity. The positioning features and openings are strategically located to provide safety without requiring complex manufacturing throughout the entire structure.
Data Source
AI summary
An electrical connection unit for a battery pack includes a busbar having a first hole therein, a top surface and a bottom surface, an annular bushing having a top end abutting the bottom surface, a bottom end opposed to the top end and a bore hole therein registered with the first hole, a busbar cage secured to the busbar and retaining the annular bushing in abutment with the busbar, the busbar cage having a cavity therein above the top surface, and a fastener having a head portion captured within the cavity and a shank portion extending through the first hole. The annular bushing may include one or more indents formed on an outer surface thereof, and the busbar cage may include a plurality of fingers extending along the outer surface and interfacing with the one or more indents. Each finger may include a protrusion configured to rest within an indent.