Elastic Busbar Clamp Insert for Vibration-Resistant Fixing
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Solution Overview
Problem
Existing connector systems for busbar conductors in electric and hybrid vehicles are prone to failure under environmental influences such as temperature variations, moisture, dust, vibrations, and shocks, and have cumbersome assembly processes, leading to unreliable and time-consuming connections.
Innovation Solution
A connector system comprising a clamping frame with an elastic insert that is partially split at the aperture, allowing for easy assembly and deformation to securely fix conductors, while the elastic material compensates for vibrations and environmental impacts, and the integral design simplifies handling and reduces assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid fixing means are used to fix busbar conductors to vehicle parts, then mechanical strength is improved, but reliability under environmental influences deteriorates
Solution Approach 1:
The patent changes the physical state and mechanical properties of the fixing means by using an elastic material instead of a rigid one. The elastic insert can deform under external impacts such as temperature variations, moisture, dust, vibrations and shocks, thereby maintaining reliable electrical and mechanical connections while accommodating environmental influences that would otherwise break rigid fixings.
2Strength
If rigid connectors are used to fix busbar conductors, then mechanical connection strength is improved, but ease of assembly deteriorates
Solution Approach 1:
The fixing means is designed as an elastic insert that can be separately assembled into the clamping frame. The insert comprises a first aperture for receiving the conductor and is at least partially split at the first aperture, allowing the aperture to be opened for easy conductor insertion. This segmented design enables simple assembly while maintaining strong mechanical connections.
3Reliability
If the insert aperture is closed to secure the conductor, then reliability of connection is improved, but ease of operation for assembly deteriorates
Solution Approach 1:
The insert is designed with dynamic characteristics, being at least partially split at the first aperture which allows the aperture to be opened. This enables the aperture to transition between open and closed states - open during assembly for easy conductor insertion, and closed during operation for secure, reliable connection. The elastic material allows the aperture to naturally close after conductor insertion, providing both ease of assembly and connection reliability.
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 connector system provides a reliable, flexible, and cost-effective solution for fixing conductors, ensuring secure connections under various environmental conditions and simplifying the assembly process, while accommodating different conductor shapes and sizes, and meeting high-voltage requirements.
Implementation Method 1
an elastic insert, configured to be arranged within the clamping frame; wherein the insert comprises a first aperture for receiving a conductor, and wherein the insert is at least partially split at the first aperture, which allows the first aperture to be opened for receiving the conductor
Implementation Method 2
the elastic material compensates for vibrations and environmental impacts
Data Source
AI summary
A connector system for fixing one or more conductors, such as busbar conductors, includes a clamping frame, configured to be fixed to a body, such as a vehicle; and an elastic insert, configured to be arranged within the clamping frame; wherein the insert comprises a first aperture for receiving a conductor, and wherein the insert is at least partially split at the first aperture, which allows the first aperture to be opened for receiving the conductor.