Insulated Busbar Connection Casing for Compact Battery Assembly
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Solution Overview
Problem
Existing electrical connection systems for busbars in tight spaces, such as within vehicle batteries, are bulky and difficult to assemble, lacking a space-saving solution with effective insulation to prevent short circuits.
Innovation Solution
An insulated connection system featuring an electrically insulating casing with a Busbar Positioning Assurance (BPA) member and anchor/locking units, allowing precise alignment and secure anchoring of busbars and connectors, ensuring correct positioning and insulation while simplifying assembly and reducing volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional line connection system is used to provide electrical insulation, then insulation is achieved, but the system becomes bulky and cannot be mounted in tight spaces
Solution Approach 1:
The patent combines multiple functions into a single integrated insulating casing structure that provides electrical insulation, positioning, alignment, and anchoring functions simultaneously, eliminating the need for separate bulky insulation components and reducing overall system volume while maintaining insulation effectiveness
Solution Approach 2:
The insulating casing serves multiple functions: it provides electrical insulation, positions the busbar and connector, aligns connection elements through recess portions, and anchors components via integrated anchor units. This multi-functionality reduces the number of separate components needed, achieving compact dimensions suitable for tight spaces
2Volume of moving object
If connection elements are closely positioned to save space, then volume is reduced, but alignment precision and positioning accuracy deteriorate
Solution Approach 1:
The insulating casing is pre-formed with recess portions that define connection orifices and accommodate connection elements in predetermined positions. This preliminary structuring of alignment features within the casing ensures precise positioning is achieved automatically during assembly, even when components are closely spaced
Solution Approach 2:
The insulating casing acts as an intermediary structure that mediates between the busbar and connector, providing built-in alignment features through its recess portions. These recesses guide and position connection elements with high precision, eliminating the need for additional alignment mechanisms while maintaining accuracy in compact configurations
3Ease of operation
If assembly is simplified by reducing components, then ease of assembly improves, but reliability of insulation and positioning may worsen
Solution Approach 1:
Multiple critical functions (insulation, positioning, alignment, anchoring) are merged into the single insulating casing structure. This integration simplifies assembly by reducing the number of components to handle while maintaining all necessary functions for reliable insulation and positioning, as the casing performs all roles simultaneously
Solution Approach 2:
The insulating casing is designed as a universal component that performs insulation, structural positioning, alignment guidance, and anchoring functions all in one piece. This multi-functionality reduces assembly complexity while ensuring reliability, as the single casing structure provides all necessary protections and positioning without requiring multiple separate components
Data Source
AI summary
An insulated connection system for connecting a first busbar and a second busbar to at least a first connector and a second connector. The second busbar including a bar orifice to connect the first connector to the first busbar. The insulated connection system including an electrically insulating casing defining: a first recess portion for accommodating a first connecting portion of the first busbar, a second recess portion for accommodating a second connecting portion of the second busbar, and a sleeve portion for accommodating a portion of the second busbar provided with the bar orifice. The insulated connection system further including a busbar positioning assurance (BPA) member of electrically insulating material configured to accommodate a portion of the first connector and to be received in the connector passage and the bar orifice.