Bus Bar Connector Assembly for Tight Battery Module Gaps
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Solution Overview
Problem
The limited space between battery modules in motor vehicles, such as hybrid or electric vehicles, complicates the installation of bus bars for electrical conduction, and existing bus bar designs are often complex and not reusable if module arrangements change.
Innovation Solution
A connection means featuring a male and female part that fit together through a translation movement along a first axis followed by a rotational movement of a quarter turn, ensuring secure and efficient electrical junction with enhanced contact areas for reliable conduction, allowing for flexible assembly and reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a compact busbar design is used to maximize energy storage capacity, then the space between modules is minimized, but the installation complexity increases
Solution Approach 1:
The busbar is divided into multiple sections with male and female connection parts, allowing modular assembly in confined spaces. Each section can be independently positioned and connected, simplifying installation while maintaining compact overall design.
Solution Approach 2:
The connection mechanism incorporates rotational movement (quarter turn) and translational movement to transform the assembly process from rigid positioning to dynamic engagement, enabling easier installation in limited space while securing reliable electrical connection.
2Reliability
If a complex busbar structure is designed to fit specific module arrangements, then electrical conduction is optimized, but reusability decreases
Solution Approach 1:
The male and female connection parts are designed with standardized interfaces that can accommodate different module arrangements. The universal connection mechanism maintains reliable electrical conduction while enabling the busbar to be reused across various configurations and applications.
Solution Approach 2:
The rotational and translational movement mechanism provides adaptive positioning capability, allowing the busbar to accommodate different module arrangements while maintaining optimal electrical contact through the progressive engagement of connection surfaces.
3Productivity
If a single-operation busbar installation is performed, then assembly time is reduced, but assembly difficulty increases
Solution Approach 1:
The busbar is segmented into modular sections with integrated male and female connection parts, enabling rapid assembly through simple connection operations rather than complex single-step installation, thus maintaining productivity while reducing difficulty.
Solution Approach 2:
The dynamic connection mechanism with rotational and translational movements transforms a potentially complex single-operation assembly into a guided multi-degree-of-freedom engagement process, reducing assembly difficulty while maintaining fast installation speed.
Data Source
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AI summary
The invention relates to a connecting means intended for providing the electrical junction between a first portion (20) of an electrically conducting bus bar (13) and a second portion (50) of said bus bar (13), comprising a male portion (30) intended for being secured to the first portion (20) of the bus bar (13), and a female portion (60) intended for being secured to the second portion (50) of the bus bar (13), the male portion (30) and the female portion (60) being able to fit into one another respectively by following a first translational movement of the female portion (60) relative to the male portion (30) along a first axis, followed by a second rotational movement of the female portion (60) relative to the male portion (30) about a second axis perpendicular to the first axis.