Elastic Electrode Clamp Assembly for Busbar Tolerance Compensation
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Solution Overview
Problem
Existing battery systems require multiple components and complex assembly processes, particularly in connecting battery units and busbars, which increases costs and complexity, especially in applications like electrical vehicle motors where tolerance and alignment issues are prevalent.
Innovation Solution
The integration of a clamp as a part of the battery unit's electrode, featuring elastically deformable legs and a transition section that allows for adjustable contact with busbars, providing a secure and adaptable connection with reduced parts and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate clamps are used to secure the connection between electrode and busbar, then the connection reliability is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The clamp is integrated as an integral part of the electrode structure, merging two previously separate components (electrode and clamp) into one unified element. This reduces the total number of parts while maintaining the secure connection function, directly resolving the contradiction between connection reliability and device complexity
2Adaptability or versatility
If flexible conductors are used to compensate tolerance between electrodes, then the adaptability is improved, but the manufacturing cost increases
Solution Approach 1:
The electrode structure incorporates elastic deformability as a key parameter, allowing the electrode to flex and adapt to tolerance variations in the battery assembly. This eliminates the need for expensive flexible conductors while maintaining adaptability, resolving the contradiction between tolerance compensation and manufacturing cost
3Stability of the object's composition
If multiple separate components are used for battery connection, then the connection stability is improved, but the assembly time increases
Solution Approach 1:
By integrating the clamp into the electrode as a single integral component, the assembly process is simplified from multiple separate installation steps to a single integrated unit installation, reducing assembly time while maintaining connection stability through the unified structure
Solution Approach 2:
The clamp is pre-integrated into the electrode structure during electrode manufacturing, so that the connection mechanism is already in place before battery assembly begins. This preliminary integration eliminates the need for separate clamp installation steps during final assembly, reducing assembly time while ensuring stable connections
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 reduces the number of components needed, simplifies assembly, and enhances tolerance compensation, ensuring reliable and low-resistance electrical contact despite mechanical and geometric variations, such as misalignments and temperature changes, thereby improving the stability and efficiency of battery systems in demanding applications.
Implementation Method 1
The transition section and/or the first leg and/or the second leg being further elastically deformed in the fourth state than in the third state
Data Source
AI summary
A battery unit is provided. A high current power supply system comprising the battery unit is also disclosed. The battery unit comprises an electrode. The electrode further comprises a clamp.The clamp includes a transition section connectinga first leg arranged at one end of the transition section,to a second leg arranged at the opposite end of the transition section.The transition section and/or the first leg and/or the second leg are elastically deformable.The clamp has a first state wherein a reference part of the first leg is distanced from a reference part of the second leg.The clamp has a second state wherein the reference part is distanced from the reference part by a second amount.The transition section and/or the first leg and/or the second leg are more elastically deformed in the second state than in the first state.