Coaxial Busbar Connection Assembly for Compact High-Current Routing
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Solution Overview
Problem
Existing busbar connection systems in electric vehicles are often bulky, inefficient, and lack ease of installation, while requiring high reliability and safety for handling high currents.
Innovation Solution
A system for connecting two separate busbars to a coaxial busbar using a housing assembly with intermediate busbars and touch-protected fastening elements, ensuring precise positioning and electrical conductivity, mechanical integrity, and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional busbar connection systems are used, then electrical conductivity can be maintained, but the system becomes bulky and installation space is wasted
Solution Approach 1:
The patent implements a nested structure where the first and second intermediate busbars are arranged coaxially within the housing assembly. The first intermediate busbar is positioned inside the same housing as the second intermediate busbar, with both connecting to the coaxial busbar in a nested configuration. This nesting approach significantly reduces the overall volume and installation space required while maintaining reliable electrical connections for high current transmission.
2Volume of moving object
If compact connection systems are implemented, then installation space is reduced, but mechanical integrity and electrical conductivity may be compromised
Solution Approach 1:
The patent divides the connection system into separate modular components: a housing assembly containing the first intermediate busbar, and a second housing assembly containing the second intermediate busbar. Each housing assembly is independently designed and manufactured, then assembled together. This segmentation allows for optimized mechanical strength in each component while achieving overall system compactness through modular integration.
Solution Approach 2:
The patent employs composite construction with housing assemblies made from materials optimized for both mechanical strength and electrical properties. The intermediate busbars are designed as composite structures combining conductive materials with mechanical support elements, ensuring high mechanical integrity while maintaining excellent electrical conductivity in a compact form factor.
3Loss of energy
If intermediate busbars are used for connections, then electrical conductivity is improved, but the device complexity increases
Solution Approach 1:
The housing assembly serves multiple functions simultaneously: it provides mechanical support for the intermediate busbars, ensures electrical insulation between components, facilitates thermal management, and enables easy installation through standardized interfaces. This multi-functionality reduces the need for separate dedicated components, thereby lowering overall system complexity while maintaining low energy loss through optimized electrical pathways.
4Reliability
If touch-protected fastening elements are implemented, then safety is improved, but manufacturing complexity increases
Solution Approach 1:
The patent introduces touch-protected fastening elements as intermediary components that provide safety functionality without complicating the core manufacturing process. These fastening elements are designed as standardized, pre-fabricated components that can be easily integrated into the housing assemblies during final assembly, ensuring operator safety while maintaining manufacturing simplicity through modular design and standardized interfaces.
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 system achieves compactness, high electrical conductivity, reduced energy losses, and enhanced safety with robust mechanical stability and easy installation, suitable for electromobility applications.
Implementation Method 1
The current-conducting connection between the first intermediate busbar and the one busbar of the coaxial busbar and/or the current-conducting connection between the second intermediate busbar and the other busbar of the coaxial busbar is or are configured as a cohesive bond connection
Implementation Method 2
The system comprises at least one threaded sleeve which is fastened to one of the two separate busbars, in particular inserted into an opening in the latter, and screwed to a touch-protected screw
Implementation Method 3
The threaded sleeves are preferably made of steel in order to withstand higher mechanical loads
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The system (20) presented for connecting two separate busbars (6a, 6b) to a coaxial busbar (4) optimizes the electrical connection in electromobility and energy storage systems. An innovative housing assembly (2, 3) integrates specific receptacles (10, 7a, 7b) for coaxial busbars (4) and separate busbars (6a, 6b), supported by intermediate busbars (5a, 5b) that are connectable in an electrically conductive manner, in particular connectable in a cohesive bond manner. The connection assembly (1) presented facilitates efficient and safe assembly and provides flexibility for various applications. The invention addresses the challenges of electromobility and energy distribution by providing a robust and adaptable solution for the integration in compact as well as power-intensive systems, making it an attractive choice for advanced applications.