Segmented Busbar Insulation Cover Assembly to Prevent Exposure Gaps
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Solution Overview
Problem
The existing insulation layers on busbars are prone to scratching or falling off, leading to a risk of electric shock for users, compromising the safety and reliability of battery systems.
Innovation Solution
A busbar assembly with a series of interconnected insulation covers that wrap around the busbar, featuring plug-fit connections and a design that prevents exposure gaps, ensuring stable and reliable insulation through a combination of slots, protrusions, and snap-fit mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation layer is coated on the surface of the busbar, then insulation protection is provided, but the insulation layer is easy to be scratched or fall off during use
Solution Approach 1:
The patent divides the insulation cover into multiple segments that can be assembled around the busbar. Each segment is a separate component that can be independently installed and removed, providing modular insulation protection that is more durable than a single coated layer.
Solution Approach 2:
The patent introduces an insulation cover as an intermediary component between the busbar and the external environment. This cover acts as a protective mediator that prevents direct contact and mechanical damage to the busbar surface, solving the problem of insulation layer durability.
2Reliability
If insulation covers are used to wrap around the busbar, then insulation performance is improved, but the complexity of the assembly increases
Solution Approach 1:
The insulation cover is divided into multiple segments that can be separately manufactured and assembled. This segmentation reduces the complexity of manufacturing each individual segment while maintaining overall insulation performance, as each segment is simpler than a complete continuous cover.
Solution Approach 2:
The insulation cover segments are designed with universal features that allow them to be used on different busbar sizes and configurations. The segments can accommodate various busbar dimensions through adjustable clamping mechanisms, reducing the need for multiple specialized components.
3Adaptability or versatility
If multiple insulation covers are connected end to end, then adaptability to different busbar lengths is achieved, but the connection reliability between covers may be compromised
Solution Approach 1:
The insulation cover segments are pre-assembled with connection structures that ensure reliable joining when installed. The connection mechanisms are designed and tested in advance to guarantee electrical isolation and mechanical strength, eliminating the need for complex field assembly procedures.
Solution Approach 2:
The patent replaces simple mechanical connections between insulation cover segments with more reliable connection methods. Electrical isolation is achieved through integrated insulating connection structures that combine mechanical fastening with electrical isolation, rather than relying solely on mechanical joints.
Data Source
AI summary
A busbar assembly includes a busbar and a plurality of insulation covers, and the respective insulation covers are connected end to end and wrap around the busbar. A battery includes a plurality of battery modules and the above-mentioned busbar assembly, and the respective battery modules are connected by the busbar assembly. An electric device includes the above-mentioned battery.