Filter Assembly Mechanical Clamping Busbar Connection
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Solution Overview
Problem
The existing methods for connecting electrical filter components, especially capacitors, to busbars in electric vehicles are time-consuming, costly, and prone to errors due to the need for welding, which affects the quality of the electrical contact.
Innovation Solution
A filter arrangement where electrical filter components are mechanically clamped between busbars, eliminating the need for welding and using a carrier element with spring-like contact sections to ensure reliable and efficient electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect filter components to busbars, then electrical connection is achieved, but production time increases and costs rise
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical clamping system using a carrier element that has spring-like contact sections. These contact sections are elastically deformable and press against the busbar surfaces to create electrical connections without welding, thereby reducing production time while maintaining connection reliability
Solution Approach 2:
The patent changes the connection method from permanent welding to reversible mechanical clamping. The carrier element can be installed and removed without damaging the busbars or filter components, allowing for maintenance and replacement while reducing production time and costs
2Reliability
If welding is used to connect filter components to busbars, then electrical connection is established, but production costs increase
Solution Approach 1:
The patent replaces the expensive welding process with a simpler mechanical clamping system. The carrier element with spring-like contact sections provides reliable electrical connection through elastic deformation and pressure contact, eliminating the need for welding equipment, trained welders, and post-weld inspection, thereby reducing production costs
Solution Approach 2:
The carrier element is designed as a cost-effective component that can be easily manufactured and replaced. Instead of investing in expensive welding infrastructure and skilled labor, the patent uses an affordable mechanical clamping solution that achieves the same electrical connection function at lower cost
3Reliability
If welding is used to connect filter components to busbars, then connection is achieved, but error rate increases due to quality fluctuations
Solution Approach 1:
The patent changes from welding (which produces irreversible connections with variable quality) to mechanical clamping with spring-like contact sections. The elastic deformation of the contact sections provides consistent contact pressure and reliable electrical connection without the quality fluctuations inherent in welding processes
Solution Approach 2:
The patent replaces welding with a mechanical clamping system that uses elastic deformation to maintain consistent contact pressure. This eliminates the quality fluctuations associated with welding variables such as heat input, electrode positioning, and operator skill, resulting in more consistent electrical contact quality
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 method reduces production costs and minimizes errors in electrical contacting, providing a reliable and efficient means to filter out high-frequency interference while maintaining low impedance connections.
Implementation Method 1
contact sections having at least one contact area in the form of a spring which can be at least partially elastically deformed or compressed when the carrier element is clamped between the busbars
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention relates to a filter arrangement comprising at least a first busbar (2) and a second busbar (3) as well as a support element (4) on which at least one electrical filter element (5, 6) is arranged, which is electrically connected to at least one of the busbars (2, 3), wherein the electrical connection of the at least one electrical filter element (5, 6) to at least one of these busbars (2, 3) is effected by mechanically clamping the support element (4) between the first and second busbar (2, 3).