Floating Busbar Connection Structure for Misalignment Tolerance

Solution Overview

Problem

The use of aluminum busbars or rods in electric vehicle charging systems results in high rigidity and lack of flexibility, leading to difficult electrical connections due to manufacturing tolerances and installation misalignments, often causing large tensile stresses.

Innovation Solution

An electrical connection device with oblong connection holes and a bolt assembly that allows for transverse and longitudinal movement of electrical transmission members, along with an elastic conductive member for floating electrical connection, accommodating misalignments and reducing connection difficulty.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum busbars or solid aluminum rod conductors are used to replace traditional copper-core wires, then the manufacturing cost is reduced and current-carrying capacity is improved, but the rigidity increases and flexibility decreases

Engineering Contradiction:

Improvecurrent-carrying capacityVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The electrical transmission member is divided into multiple sections that can relatively move against each other, with each section connected through connection holes and fastening structures. This segmentation allows the rigid aluminum busbar to be divided into flexible segments that can accommodate misalignments while maintaining high current-carrying capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection structure transforms from a fixed rigid connection to a dynamic flexible connection. The first and second electrical transmission members can move relative to each other in longitudinal and transverse directions, allowing the system to adapt to manufacturing tolerances and installation misalignments while maintaining electrical connectivity.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If aluminum busbars with high rigidity are used, then the manufacturing cost is reduced, but the difficulty of electrical connection operations increases due to manufacturing tolerances and installation misalignments

Engineering Contradiction:

Improvemanufacturing costVSAvoidconnection difficulty

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The connection structure transforms from a fixed rigid connection to a dynamic flexible connection. The first and second electrical transmission members can move relative to each other in longitudinal and transverse directions, allowing the system to adapt to manufacturing tolerances and installation misalignments while maintaining electrical connectivity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The connection holes are designed with specific dimensional parameters (larger than the electrical transmission members) to create clearance that accommodates misalignments. This parameter change from tight-fit to clearance-fit connections enables easier assembly while maintaining structural integrity.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If traditional fixed connection methods are used with rigid aluminum busbars, then the structural stability is maintained, but large tensile stresses occur due to installation misalignments

Engineering Contradiction:

Improvestructural stabilityVSAvoidtensile stress

Core Design Contradiction:

Stability of the object's compositionVSStress or pressure

Solution Approach 1:

The connection structure transforms from a fixed rigid connection to a dynamic flexible connection. The first and second electrical transmission members can move relative to each other in longitudinal and transverse directions, allowing the system to adapt to manufacturing tolerances and installation misalignments while maintaining electrical connectivity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The design anticipates potential misalignments and manufacturing tolerances by providing clearance in the connection holes and relative movement capability before assembly. This beforehand cushioning prevents excessive tensile stresses from developing during installation by allowing natural adjustment to the optimal position.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS20260011933A1Electrical connection device and electrical connection method

Publication Date: 2026.01.08 TYCO ELECTRONICS (SHANGHAI) CO LTD

AI summary

An electrical connection device includes a housing, a first electrical transmission member inserted into the housing and having a first connection hole, and a second electrical transmission member inserted into the housing and having a second connection hole. The electrical connection device includes a bolt assembly entering the housing and including a bolt passing through the first connection hole and the second connection hole, and a nut assembly threadedly connected to the bolt to fasten the first electrical transmission member and the second electrical transmission member together. The first connection hole is oblong and enables the end of the first electrical transmission member to move in a transverse direction relative to the bolt, the second connection hole is oblong and enables the end of the second electrical transmission member to move in a longitudinal direction relative to the bolt.