Flexible Busbar Connector for Battery Module Tolerance Compensation
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Solution Overview
Problem
High-voltage storage systems for motor vehicles require efficient electrical connection of battery modules, which is currently time-consuming due to manufacturing tolerances and requires significant assembly time, necessitating a solution for simple and tolerant compensation.
Innovation Solution
A plug-in module connector with a flexible busbar and U-shaped clamps for tolerance compensation in all spatial directions, along with an insulation housing and contact protection caps, allowing for easy assembly and reliable electrical connection of battery modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections with busbars are used to connect battery modules, then reliable electrical connection is achieved, but assembly time increases significantly
Solution Approach 1:
The connection system is divided into modular components: a connector with integrated busbar, clamps, and insulation housing that can be assembled as a single unit and then connected to battery modules. This segmentation allows pre-assembly of complex components while simplifying the final connection step, reducing overall assembly time while maintaining connection reliability.
Solution Approach 2:
The traditional screw connection mechanism is replaced with a clamp-based mechanical fastening system. The clamps embrace the busbar and pole, providing secure electrical connection through friction and geometric constraint rather than threaded fastening, significantly reducing assembly time while maintaining connection reliability.
2Stability of the object's composition
If rigid busbars and clamps are used for connection, then structural stability is ensured, but tolerance compensation becomes difficult
Solution Approach 1:
The busbar is designed with flexible sections that can deform elastically to accommodate misalignments between battery module poles. This dynamic flexibility allows the rigid-clamped connection to adapt to manufacturing tolerances while maintaining stable electrical contact, resolving the contradiction between structural stability and tolerance compensation.
Solution Approach 2:
The busbar incorporates flexible metallic sections that can bend and deform to compensate for positional variations in battery module poles. This flexibility enables the connection system to absorb manufacturing tolerances in all spatial directions while maintaining reliable electrical connection and structural stability.
3Manufacturing precision
If complex tolerance compensation mechanisms are added, then manufacturing tolerances are accommodated, but device complexity increases
Solution Approach 1:
Multiple functions are merged into a single integrated connector assembly: the busbar provides electrical connection, the clamps provide mechanical fastening and positioning, and the insulation housing provides electrical isolation and structural support. This integration achieves comprehensive tolerance compensation without requiring separate complex adjustment mechanisms for each function.
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: electrical conduction, mechanical fastening, positional adjustment, and electrical insulation. The flexible busbar and clamp combination provides universal tolerance compensation in all spatial directions while maintaining a relatively simple overall structure, avoiding the need for separate adjustment mechanisms.
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
Significantly reduces assembly time by enabling easy plugging and tolerance compensation in all directions, facilitating rapid connection of multiple battery modules with minimal force and ensuring reliable, high-conductivity connections.
Implementation Method 1
a flexible busbar for the electrically conductive connection of respective poles (16, 18) of the battery modules (12, 14), wherein the busbar enables a tolerance balance with respect to the poles (16, 18) in the transverse direction of the module connector
Implementation Method 2
two retaining clamps (24) for embracing the busbar (20) and one of the respective poles (16, 18) of the battery modules (12, 14), whereby the retaining clamps allow for tolerance compensation with respect to the poles (16, 18) in the longitudinal and vertical direction of the module connector
Implementation Method 3
a flexible busbar for the electrically conductive connection of respective poles (16, 18) of the battery modules (12, 14)
Data Source
AI summary
The present disclosure relates to a plug-in module connector or the electrically conductive connection of at least two battery modules, including a flexible busbar for the electrically conductive connection of respective poles of the battery modules, the busbar enabling tolerance compensation with respect to the poles in the transverse direction of the module connector; two retaining clamps for gripping the busbar and one of the respective poles of the battery modules, the retaining clamps enabling tolerance compensation with respect to the poles in the longitudinal direction and vertical direction of the module connector; an insulation housing in which the retaining clamps plugged onto the busbar can be received. Furthermore, the present disclosure also concerns a method for the electrically conductive connection of at least two battery modules by means of a plug-in module connector.