Deformed Attachment Structure for Busbar to Battery Terminal Connection

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Solution Overview

Problem

Conventional methods for securing busbars in electrified vehicles, such as welding or mechanical fasteners, can lead to defects like intermetallic brittleness, porosity, and cracks, and require additional components, increasing complexity and profile.

Innovation Solution

A busbar assembly that uses a deformed area of an attachment structure, featuring an array of fins and a collar circumferentially distributed about an axis, which is bent radially outward to secure the busbar to a battery terminal without the need for welds or mechanical fasteners, forming a monolithic structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding or mechanical fasteners are used to secure the busbar, then the busbar can be securely attached to the battery terminal, but defects like intermetallic brittleness, porosity, and cracks occur, and additional components are required increasing complexity and profile

Engineering Contradiction:

Improveattachment reliabilityVSAvoidattachment structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The attachment structure is merged with the battery terminal to form a monolithic integrated component. The attachment structure includes a first portion that receives the busbar and a second portion that is deformed to secure the busbar, eliminating the need for separate fasteners or welding operations. This integration reduces the number of components and eliminates defects associated with traditional joining methods.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The attachment structure performs multiple functions through its own structural features without requiring external fasteners or welding. The first portion provides reception and alignment for the busbar, while the second portion self-secures the busbar through deformation, making the system self-sufficient and eliminating dependency on additional components or thermal processes.

Inventive Principle:

Principle #25Self-service

2Strength

If welding is used to secure the busbar, then a strong attachment is achieved, but thermal energy is required which can cause intermetallic brittleness, porosity, and cracks

Engineering Contradiction:

Improveattachment strengthVSAvoidthermal defects

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical deformation process. Instead of using thermal energy to join the busbar to the terminal, the second portion of the attachment structure is mechanically deformed to secure the busbar. This substitution eliminates thermal defects such as intermetallic brittleness, porosity, and cracks while maintaining strong attachment through mechanical interlocking.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If mechanical fasteners are used to secure the busbar, then the attachment can be made without thermal energy, but additional components are required increasing complexity and profile

Engineering Contradiction:

Improvethermal defect avoidanceVSAvoidnumber of components

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

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

This solution eliminates weld defects and reduces complexity by securing the busbar directly to the terminal, providing a low-profile, reliable connection that does not require thermal energy or separate mechanical fasteners.

Implementation Method 1

deforming a second portion of the attachment structure to provide a deformed area

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

pressing a punch relative to the attachment structure to provide the deformed area

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Data Source

PatentUS10854865B2Electrified vehicle busbar secured using a deformed area of an attachment structure

Publication Date: 2020.12.01 FORD GLOBAL TECH LLC

AI summary

A busbar assembly includes, among other things, a busbar, a battery terminal, and a deformed area securing together the busbar and the battery terminal. A securing method includes, among other things, positioning a first portion of an attachment structure within an aperture, deforming a second portion of the attachment structure to provide a deformed area, and using the deformed area to secure a busbar relative to a battery terminal.