Modular Busbar Contact Assembly Without Welding

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Solution Overview

Problem

Existing busbars used for transmitting high electrical currents face manufacturing restrictions due to their one-piece design or welding requirements, limiting geometry and material choices, especially in decentralized battery applications.

Innovation Solution

A modular contact assembly comprising a contact element with a lead-through opening and collar section, a busbar with a reception opening, and a fastener, utilizing frictional surfaces and deformations to securely connect without welding, allowing for complex geometries and diverse materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If busbars are manufactured in one piece with contact sections by forging or extrusion, then manufacturing simplicity is improved, but geometric flexibility and adaptability deteriorate due to constructional restrictions

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidgeometric flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The busbar system is divided into separate components: a busbar body and a contact section that can be manufactured independently and then assembled together. This segmentation allows each component to be optimized separately - the busbar can have complex geometries while the contact section provides standardized connection functionality, resolving the contradiction between manufacturing simplicity and geometric flexibility.

Inventive Principle:

Principle #1Segmentation

2Strength

If contact sections are welded to the busbar, then connection strength is improved, but material selection freedom deteriorates due to weldability requirements

Engineering Contradiction:

Improveconnection strengthVSAvoidmaterial selection freedom

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The welding process is replaced with a mechanical pressing connection system. The contact section is pressed onto the busbar to create an electrically conductive and mechanically robust connection without requiring welding. This substitution eliminates weldability constraints, allowing free selection of materials based on electrical and mechanical properties rather than welding compatibility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If busbars have complex profiles for decentralized applications, then adaptability to distributed battery modules is improved, but manufacturing complexity deteriorates

Engineering Contradiction:

Improveprofile complexityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By segmenting the busbar system into a standardizable body and a separate contact section, the complex profile requirements can be met through modular assembly rather than complex monolithic manufacturing. The contact section with its specific geometry can be pressed onto the busbar body, allowing complex overall profiles to be achieved through simple component assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact sections are pre-manufactured with their specific geometries and connection features, then assembled to the busbar body in a preliminary preparation step. This allows complex profiles to be achieved by combining pre-fabricated components rather than manufacturing the entire complex structure in one process.

Inventive Principle:

Principle #10Preliminary action

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

Enables flexible manufacturing and material selection, improving the manufacturability and conductivity of busbars for complex profiles without the need for welding, suitable for decentralized battery applications.

Implementation Method 1

The contact element has a first friction surface affixable with the busbar in the reception opening in a frictionally engaging manner and a second friction surface affixable in the reception opening with the busbar or in the lead-through opening with the fastener in a frictionally engaging manner

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12506225B2Contact as module connector, connection assembly, battery cell and battery module with such contact assemblies

Publication Date: 2025.12.23 TE CONNECTIVITY GERMANY GMBH

AI summary

A contact assembly includes a contact element having a lead-through opening, a contact section extending in a tube-shaped manner along the lead-through opening and having a contact surface, and a collar section connected to the contact section and extending the lead-through opening in a sleeve-shaped manner, a busbar having a reception opening receiving the collar section, and a fastener inserted into the lead-through opening. The contact element has a first friction surface affixable with the busbar in the reception opening in a frictionally engaging manner and a second friction surface affixable in the reception opening with the busbar or in the lead-through opening with the fastener in a frictionally engaging manner. The first friction surface and the second friction surface are mutually offset in a radial direction with respect to the lead-through opening.