Clip Element Spring Limbs for Busbar Connection
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Solution Overview
Problem
Existing busbar connection techniques, such as screw connections, are unsuitable for secure and reliable electrical and mechanical connections in electrified vehicles due to complexity and space constraints, requiring a more efficient and cost-effective solution.
Innovation Solution
A clip element with spring limbs that presses a conductor arrangement and busbar together, utilizing interlocking surface structures and latching mechanisms for secure mechanical and electrical connections, allowing for simple assembly and reduced installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connection techniques are used for busbars, then reliable electrical connection is achieved, but device complexity and production complexity increase
Solution Approach 1:
The patent replaces the traditional screw connection system with a clip element that uses elastic spring limbs to create a mechanical press connection. This substitution eliminates the need for threading operations, screw fasteners, and associated tooling, thereby reducing production complexity while maintaining connection reliability through continuous elastic pressure between contact surfaces
Solution Approach 2:
The invention extracts and eliminates unnecessary components from the traditional screw connection system, retaining only the essential function of electrical contact. The clip element design removes screws, nuts, and complex fastening mechanisms, keeping only the minimal structure needed to press the conductor arrangement against the busbar, thus simplifying production
2Reliability
If traditional connection techniques are used for busbars, then secure mechanical connection is achieved, but installation space requirements increase
Solution Approach 1:
The patent employs dynamic elastic spring limbs that can deflect and adapt to slight variations in assembly tolerances and thermal expansion. This dynamic capability allows the connection to maintain secure mechanical contact without requiring large adjustment spaces or complex positioning mechanisms, thereby reducing installation space while ensuring connection security
Solution Approach 2:
The clip element utilizes flexible spring limbs made from elastic material that can deform within a compact volume. These flexible elements provide the necessary mechanical pressure and adaptability without requiring the bulky rigid structures typical of traditional mechanical connections, thus reducing installation space requirements
3Device complexity
If clip element with spring limbs is used, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the contact interface into distinct contact areas on the busbar and conductor arrangement, with the spring limbs providing localized pressure at these segmented points. This segmentation allows each contact area to be optimized independently and tolerates variations in overall alignment, reducing the stringency of manufacturing precision requirements while maintaining connection quality
4Stability of the object's composition
If surface structures for interlocking are added, then lateral displacement prevention is improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates surface structures with curved or rounded features on the contact areas of the busbar and conductor arrangement. These curved surface structures provide interlocking capability to prevent lateral displacement while being compatible with standard forming and machining processes, thus maintaining ease of manufacture unlike sharp or complex geometric features
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 secure, reliable, and cost-effective electrical connection that prevents lateral displacement, facilitating easy assembly and reducing production complexity while accommodating multiple current-conducting plates in a space-efficient manner.
Implementation Method 1
The spring limbs (170, 180) are designed to press the busbar (110) and the conductor arrangement (120) against one another
Data Source
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AI summary
The invention describes an electrical connection arrangement (100) comprising: - a busbar (110) with a first contact area (116), - a conductor arrangement (120), which rests on the first contact area (116) of the busbar (110) by way of a second contact area (122) and is electrically connected to the busbar (110) by means of the contact areas (116, 122), composed of at least one current-conducting plate (130, 140), and - a clip element (160) with a first spring limb (170) which bears on a bottom side (112) of the busbar (110), a second spring limb (180) which rests on a top side (132, 142) of the conductor arrangement (120), and a connecting section (190) which connects the first and the second spring limb (170, 180) to one another, wherein the spring limbs (170, 180) are designed to press the busbar (110) and the conductor arrangement (120) against one another by way of their two contact areas (116, 122) in order to create a mechanical connection between the busbar (110) and the conductor arrangement (120).