Finger-Proof Busbar Connector With X-Y Float for Battery Assembly

Solution Overview

Problem

Current terminal connectors in electrochemical energy storage devices, such as Li-ion batteries, require precise placement and dimensional tolerancing for automated assembly, which is challenging due to lack of sliding movement features, limiting their applicability in modular battery systems.

Innovation Solution

A busbar assembly with finger-proof terminal connectors allowing limited movement within the x-y plane, featuring slots and protective coatings, and terminal caps for automated assembly, enabling secure electrical connections while preventing accidental contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If traditional terminal connectors are used, then precise placement and dimensional tolerancing are required for automated assembly, but this increases assembly complexity and reduces adaptability

Engineering Contradiction:

Improveautomated assembly capabilityVSAvoidplacement precision

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The terminal connector incorporates a sliding mechanism that allows the distal end of the busbar to move relative to the terminal connector body within an x-y plane. This dynamic adjustment capability enables the connector to accommodate variations in module placement positions, allowing automated assembly without requiring extremely tight tolerances. The sliding feature dynamically adapts to different module positions while maintaining reliable electrical connection.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If terminal connectors without sliding movement are used, then assembly precision can be maintained, but adaptability to different module placements is reduced

Engineering Contradiction:

Improveadaptability to module placementVSAvoidplacement precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The terminal connector incorporates a sliding mechanism that allows the distal end of the busbar to move relative to the terminal connector body within an x-y plane. This dynamic adjustment capability enables the connector to accommodate variations in module placement positions, allowing automated assembly without requiring extremely tight tolerances. The sliding feature dynamically adapts to different module positions while maintaining reliable electrical connection.

Inventive Principle:

Principle #15Dynamics

3Object-affected harmful factors

If finger-proof terminal connectors are used, then safety is improved, but the complexity of the terminal connector structure increases

Engineering Contradiction:

Improvesafety from accidental contactVSAvoidterminal connector structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The terminal connector employs a nested structure where terminal caps enclose the electrified terminal surfaces. The terminal caps are positioned to surround the conductive elements, creating a protective enclosure that prevents finger access to live surfaces. This nesting approach integrates safety functionality within the existing connector geometry without adding significant external complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The terminal caps function as protective shells that enclose the electrified surfaces. These caps are designed to fit over the terminal structures, creating a physical barrier that prevents accidental contact while maintaining a relatively simple overall structure. The shell-like protection is achieved through strategically positioned caps rather than comprehensive enclosures.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20260018841A1Busbar with finger-proof terminal connector

Publication Date: 2026.01.15 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A busbar assembly for interconnecting components within a multi-module electrical system for a vehicle includes a busbar having a first distal end and a second distal end, and a first finger-proof terminal connector positioned on the first distal end of the busbar and adapted to electrically connect the busbar to an external terminal, wherein the finger-proof terminal connecter is adapted to allow limited movement of the first distal end of the busbar relative to the first finger-proof terminal connector within an x-y plane.