Busbar Power Connector with Locking Cap for Safe Battery Module Assembly
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Solution Overview
Problem
Current battery connection technologies in electric or rechargeable hybrid motor vehicles face challenges such as increased assembly time, risk of poor connections due to uncontrollable screwing parameters, and lack of flexibility in tolerances, leading to potential security issues and high costs.
Innovation Solution
A power connector design that separates the positioning of busbar terminals from establishing electrical contact, using a cap that locks in a delivery position to prevent unwanted electrical contact, allowing for controlled connection through a push mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwed connection systems are used to connect busbars to battery modules, then mechanical strength and connection reliability are improved, but assembly time increases and manufacturing precision becomes difficult to control
Solution Approach 1:
The patent replaces the traditional screwed mechanical connection system with a plug connection system. The busbar terminal is inserted into a connector housing and secured by a cap that locks in place, eliminating the need for screws and nuts. This substitution maintains connection reliability while dramatically reducing assembly time and eliminating the need for torque control.
Solution Approach 2:
The plug connection system is designed to be self-securing through the cap mechanism. Once the busbar terminal is inserted into the connector housing, the cap is placed and automatically locks the connection, providing self-verifying engagement without requiring external tools or complex assembly procedures.
2Strength
If screwed connection systems are used, then connection strength is improved, but manufacturing precision and tolerance control become problematic
Solution Approach 1:
The connector housing acts as an intermediary component that receives and secures the busbar terminal. The housing includes guiding features and positioning structures that ensure accurate alignment and insertion, while the cap provides secure locking. This intermediary mechanism eliminates the need for precise screw positioning and torque control.
Solution Approach 2:
The plug connection system incorporates dynamic elements including the insertable busbar terminal and the locking cap. The design allows for tolerance accommodation through the insertion and locking mechanism, providing robust connection strength without requiring tight manufacturing tolerances on positioning features.
3Productivity
If traditional plug solutions are used, then assembly time is reduced, but positioning accuracy and safety are compromised
Solution Approach 1:
The connection system is segmented into distinct functional components: the connector housing with guiding features, the busbar terminal with connection portion, and the locking cap. This segmentation allows each component to be optimized for its specific function while maintaining simple assembly. The housing provides positioning guidance, the terminal provides electrical connection, and the cap provides secure locking.
Solution Approach 2:
The connector housing serves as an intermediary that guides the busbar terminal into the correct position and secures it with the cap. The housing includes guiding portions and positioning features that ensure accurate alignment, maintaining positioning reliability while enabling quick assembly through the plug-and-lock mechanism.
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
A power connector for connecting a busbar (4) to an electrical battery module comprising an electrically insulating connector housing (6) accommodating a connector terminal (7) electrically connected to the busbar (4). the connector terminal (7) and busbar (4) are mechanically fastened into a cap (10). The cap (10), the connector terminal (7) and the busbar (4) are movable together relative to the connector housing (6) between at least a delivery position and a connection position. The cap (10) comprises cap locking means (11). The cap locking means (11) are actuatable between a locked position in which it holds the cap (10) and the connector housing (6) in the delivery position and an unlocked position wherein the cap (10) and the connector housing (6) are released so as to allow the cap (10) to be pushed into the connection position.