Busbar Connection Terminal With Rotation-Preventing Collar
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Solution Overview
Problem
Existing electrical connector solutions for high-current applications, such as busbars, face challenges including high cost, vulnerability to thermal treatment, complex assembly processes, and failure under vibration and environmental stress, particularly in high or low temperature and dusty conditions.
Innovation Solution
An electrical connector system featuring a terminal with a through-hole and a separate first element that includes a hollow portion and a collar to prevent rotation, with protrusions that press into the terminal to ensure secure contact and prevent oxidation, allowing for simplified assembly without welding and improved vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding technology (resistance welding, brazing, or ultrasonic welding) is used to connect busbar to terminal, then electrical connection reliability is improved, but manufacturing cost increases and the process becomes more complex
Solution Approach 1:
The patent replaces thermal welding processes (resistance welding, brazing, ultrasonic welding) with a purely mechanical press-fit connection system. The element is inserted into the through-hole and secured by friction and geometric constraints, eliminating the need for welding equipment, thermal management, and associated process complexity while maintaining connection reliability.
Solution Approach 2:
The connection system is divided into separate modular components: a terminal with through-hole and a separate element with collar. This segmentation allows each component to be manufactured independently using simpler processes and assembled through straightforward insertion, reducing overall manufacturing complexity compared to integrated welded solutions.
2Reliability
If welding technology is used to connect busbar to terminal, then electrical connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive welding processes with a low-cost mechanical press-fit system. The element is simply inserted into the through-hole and secured by friction and the collar structure, eliminating the need for welding equipment, energy consumption, and skilled welding operators, thereby significantly reducing manufacturing costs while maintaining connection reliability.
Solution Approach 2:
The element is designed as a simple, inexpensive mechanical component that can be mass-produced through casting or molding. Rather than using expensive welding materials (such as brazing alloys or specialized welding consumables), the system uses a cost-effective element with a collar that provides sufficient mechanical and electrical connection functionality.
3Reliability
If contact disc is used in bolt connection, then electrical connection is provided, but assembly complexity increases and the process becomes subject to failure if disc falls off
Solution Approach 1:
The patent merges the contact disc function directly into the element structure. The element itself serves as both the electrical contact component and the structural connector, eliminating the need for a separate contact disc. This integration simplifies the assembly process to a single insertion step while maintaining reliable electrical connection, and eliminates the risk of the contact disc falling off during assembly.
4Stability of the object's composition
If protrusions press into terminal to prevent rotation, then connection stability is improved, but the terminal material may be affected by deformation
Solution Approach 1:
The patent applies local quality by concentrating the deformation effect only in specific localized areas where protrusions contact the terminal wall. The majority of the terminal structure remains undisturbed and maintains its full strength. The localized deformation is sufficient to prevent rotation and provide stable positioning without compromising the overall structural integrity of the terminal.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5B
AI summary
The present invention relates to an electrical connector for connecting a conductive element to a counter connector, comprising a terminal, of the conductive element, having a first surface and defining a through-hole in the first surface extending through the terminal; a first element separate from the terminal and in engagement with the terminal; wherein the first element comprises a hollow portion extending through the through-hole of the terminal and a collar covering at least a part of a periphery of the through-hole on the first surface of the terminal, wherein a main surface of the collar facing the first surface of the terminal is structured such that rotation of the element in the through-hole is prevented. It further relates to an electrical connector system, a first element for facilitating an electrical connection, a method for assembling an electrical connection and a method for connecting an electrical connector to a counter connector.