Integral Busbar Connection With Retention for Low-Resistance Plug-In Joints
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Solution Overview
Problem
Existing busbar connection methods in electric vehicles require complex processes, increase electrical resistance, and are often one-time use, making system integration difficult.
Innovation Solution
A busbar portion with an integrally formed busbar end that includes a connection portion and retention means, allowing for a plug-in connection without screws, welds, or bolts, reducing electrical resistance and facilitating easy disassembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welded, screwed, or bolted connections are used to connect busbars with conductors, then the connection is robust and can withstand high/low temperatures, humidity, and vibrations, but the number of manufacturing steps increases and the process becomes complex
Solution Approach 1:
The busbar end is integrally formed with the busbar conductor, merging two previously separate components (busbar and terminal) into a single continuous piece. This eliminates the need for separate connection hardware (screws, bolts, welds) and simplifies the manufacturing process while maintaining connection robustness through the integral structure
Solution Approach 2:
The busbar end serves multiple functions: it provides electrical conduction (replacing separate terminals), structural support (replacing fasteners), and connection interface (replacing complex joining mechanisms). This multi-functionality reduces manufacturing steps while maintaining reliability
2Reliability
If welded, screwed, or bolted connections are used to connect busbars with conductors, then the connection is robust, but the electric resistance increases
Solution Approach 1:
By making the busbar end an integral continuation of the busbar conductor with no material boundary, the electrical path is continuous without interruption. This eliminates contact resistance at connection interfaces that would exist in welded, screwed, or bolted joints, thereby reducing overall electric resistance while maintaining mechanical robustness
3Reliability
If traditional connection methods are used, then the connection is robust, but the number of parts increases
Solution Approach 1:
The busbar end integrates the functions of the busbar conductor and the terminal into a single continuous component. This eliminates separate parts such as terminals, fasteners, and connection hardware, reducing the total number of parts while maintaining connection robustness through the integral design
4Ease of manufacture
If one-time use connections are used, then the connection is simple to manufacture, but system integration becomes difficult and requires special processes
Solution Approach 1:
The connection design allows for reversible plugging and unplugging operations. The busbar end can be repeatedly connected to and disconnected from mating connectors, enabling flexible system integration, reconfiguration, and maintenance while maintaining manufacturing simplicity through the integral structure
Data Source
AI summary
A busbar portion includes a busbar conductor and a busbar end which is integrally formed with the busbar conductor. The busbar end has a connection portion. The connection portion is configured for being plugged to a mating connector to establish an electrical connection. The busbar end further incorporates a retention means which is configured to engage with a corresponding retention means to receive pull forces being imposed on the busbar portion in a direction opposite to a mating direction.