Elastic Busbar Clamp Connector for Battery Electrode Tolerance Compensation
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Solution Overview
Problem
Existing connectors for connecting conductors, such as busbars and electrodes in high-current power supply systems, are costly due to the use of flexible conductors and do not effectively accommodate mechanical and geometric tolerances, leading to potential disconnections and increased resistance.
Innovation Solution
A clamp with elastically deformable parts and a movable spacer that facilitates easy assembly by allowing the spacer to move from a first position to a second position, accommodating geometric variations and maintaining electrical contact despite mechanical disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible conductors are used to compensate tolerance between electrodes, then adaptability to geometric variations is improved, but manufacturing cost increases
Solution Approach 1:
The connector is divided into separate functional components: a clamp body with elastically deformable legs and a transition section, and a separate spacer element. This segmentation allows each part to be manufactured independently using standard rigid materials, avoiding the need for expensive flexible conductors while maintaining adaptability through the elastic deformation capability of the clamp's transition section.
Solution Approach 2:
The transition section is designed with specific geometric parameters (width, thickness, material properties) that enable elastic deformation within a defined range. This allows the connector to adapt to geometric variations in electrode positioning through controlled elastic bending, replacing the need for flexible conductors and reducing manufacturing costs.
2Ease of manufacture
If rigid connectors are used to connect conductors, then manufacturing cost is reduced, but ability to accommodate mechanical and geometric tolerances deteriorates
Solution Approach 1:
The transition section is designed to be elastically deformable, allowing the connector to dynamically adapt its shape within elastic limits to accommodate misalignments and geometric tolerances in electrode positioning. This dynamic adaptation capability is achieved through careful selection of material properties and geometric dimensions of the transition section.
Solution Approach 2:
The elastically deformable transition section acts as a pre-designed cushioning element that absorbs geometric variations and mechanical disturbances before they can cause connection failures. The elastic deformation capacity is built into the structure beforehand, providing tolerance compensation without requiring active control mechanisms.
3Reliability
If complex assembly procedures are used to ensure reliable connection, then connection reliability is improved, but assembly time increases
Solution Approach 1:
The spacer element is pre-positioned or pre-assembled with the clamp body, and the elastically deformable legs are pre-configured to engage with the busbar in a predetermined sequence. This preliminary arrangement of components simplifies the final assembly operation, allowing the connector to be installed quickly while maintaining reliable electrical contact through the built-in elastic engagement mechanism.
Solution Approach 2:
The elastically deformable legs automatically engage with the busbar through their own elastic recovery force after insertion, without requiring additional fastening operations or external tools. The spacer element also contributes to self-alignment and secure positioning, enabling the connector to assemble itself with minimal manual intervention and ensuring reliable connection through the inherent elastic locking mechanism.
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 cost-effective and reliable connection system that maintains electrical contact under mechanical and geometric variations, reducing resistance and ensuring stable power transmission.
Implementation Method 1
the transition section and/or the first leg being elastically deformable, the clamp having a first state, in which a reference part of the first leg is distanced from a reference part of the second leg by a first amount, the clamp having a second state, in which the reference part of the first leg is distanced from the reference part of the second leg by a second amount that is different from the first amount, the transition section and/or the first leg being further elastically deformed in the second state than in the first state
Data Source
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AI summary
Connector (3) suitable to hold a busbar (4) in contact with another conductor in a high current power supply system, in particular a battery unit, in particular with an electrode (5) of a battery or with a further busbar (4), the connector (3) comprising a clamp (11), • the clamp (11) having transition section (20) connecting • a first leg (22) arranged at one end of the transition section (20), • to a second leg (23) arranged at the opposite end of the transition section (20), • the transition section (20) and/or the first leg (22) being elastically deformable, • the clamp (11) having a first state, in which a reference part (24) of the first leg (22) is distanced from a reference part (25) of the second leg (23) by a first amount, • the clamp (11) having a second state, in which the reference part (24) of the first leg (22) is distanced from the reference part (25) of the second leg (24) by a second amount that is different from the first amount, • the transitions section (20) and/or the first leg (22) being further elastically deformed in the second state than in the first state, • the transition section (20) having a width in a width direction that extends at an angle to a line that connects the one end with the opposite end of the transition section (20), the connector further comprising a spacer (12), the spacer (12) being moveable between a first position and a second position, the spacer (12) being in contact with a part of the first leg (22) when the clamp (11) is in the second state and the spacer (12) is in the first position, characterized in that the spacer (12) • is designed to be rotated from the first position into the second position or • is designed to be moved linearly from the first position into the second position along a retraction direction, the retraction direction pointing at least partially in the width direction and/or at least partially pointing towards the transition section (20) or • is designed to perform a combined rotational and linear movement from the first position into the second position.