Quick Connect Assembly for Busbar Electrical Terminals

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Solution Overview

Problem

Conventional electrified vehicles face challenges in establishing reliable and efficient electrical connections between high-current busbars and electrical components, primarily relying on threaded connections which are time-consuming and may compromise connection integrity.

Innovation Solution

A quick connect assembly using push fittings, snap-fit mechanisms, and clamping assemblies that mechanically and electrically couple busbars to electrical terminals without requiring threaded connections, ensuring durable and easy assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If threaded connections (nut and bolt) are used to couple busbars to electrical terminals, then connection reliability is maintained, but assembly time increases and productivity decreases

Engineering Contradiction:

Improveconnection integrityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the traditional threaded mechanical connection system (nuts and bolts) with a push-fit quick connect assembly that uses a spherical busbar end inserted into a socket with clamping leaves. This substitution eliminates threading operations while maintaining electrical connection reliability through the clamping action of the leaves against the spherical end.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the connection mechanism from threaded engagement to a push-fit operation where a spherical busbar end is inserted into a socket. The connection is established by pushing the spherical end into the socket, causing the clamping leaves to flex and grip the spherical end, thereby changing the connection parameter from rotational threading to linear insertion with elastic clamping.

Inventive Principle:

Principle #35Parameter changes

2Strength

If threaded connections are used to couple busbars to electrical terminals, then connection strength is ensured, but assembly complexity increases

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the complex threaded connection system with a simpler push-fit mechanism. The quick connect assembly uses a spherical busbar end that inserts into a socket with clamping leaves, eliminating the need for threading operations, nuts, and bolts, thereby reducing assembly complexity while maintaining connection strength through the clamping action.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The clamping leaves in the socket automatically engage and clamp the spherical busbar end upon insertion. The elastic leaves flex outward during insertion and then spring back to grip the spherical end, providing self-clamping functionality that eliminates the need for additional fastening operations or complex assembly procedures.

Inventive Principle:

Principle #25Self-service

3Reliability

If threaded connections are used, then electrical connection reliability is maintained, but assembly ease deteriorates

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the threaded connection system with a push-fit quick connect mechanism. The spherical busbar end is simply inserted into the socket, and the clamping leaves automatically grip it, eliminating the need for threading operations and making assembly much easier while maintaining electrical connection reliability through the secure clamping contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The clamping leaves automatically engage and secure the spherical busbar end upon insertion without requiring additional fastening operations. The elastic leaves flex during insertion and then spring back to clamp the spherical end, providing self-securing functionality that greatly simplifies the assembly operation while ensuring reliable electrical contact.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a rapid, reliable, and tool-free connection method that maintains the integrity of electrical connections, reducing assembly time and ensuring consistent performance in electrified vehicle systems.

Implementation Method 1

the end of the busbar is one of spherical-shaped and ovular-shaped, and wherein the shape of the socket corresponds to the shape of the end of the busbar

Methodology Applied

Scientific EffectGeometric shape matching: Geometry

Implementation Method 2

each layer includes a tapered end, the tapered ends mating with corresponding tapered cavities in the electrical terminal to electrically couple the busbar to the electrical terminal

Methodology Applied

Scientific EffectTapered mating geometry: Geometry

Implementation Method 3

the quick connect assembly includes a clamp assembly configured to couple the busbar to the electrical terminal by a clamping force and without a threaded connection

Methodology Applied

Scientific EffectClamping force: Mechanical Force

Data Source

PatentUS10122004B2Quick connect assembly for busbars in an electrified vehicle

Publication Date: 2018.11.06 FORD GLOBAL TECH LLC

AI summary

A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, a busbar, an array of battery cells including an electrical terminal, and a quick connect assembly mechanically and electrically coupling the busbar to the electrical terminal.